Ultrasonic horns are sized and shaped to best deliver vibratory energy to the work piece. In many cases the ultrasonic horn increases amplitude to the exact requirements of the resin.
Selecting Horn Materials Most horns are made from aluminum and titanium materials due to their high modulus of elasticity. A close examination of the application requirements will always reveal the best material choices. By answering these 5 basic questions, the proper horn material can be selected.
Q. What is the application? Welding, staking/forming, insertion, spot welding, degating, film sealing, etc.?
A. In welding applications, aluminum is a good choice. For staking, forming and spot welding, titanium horn or horn tip is required. For insertion, titanium horn/tip or possibly hardened steel is best at combating wear. For film sealing and other high wear applications consider titanium at a minimum, hardened steel, or carbide coating.
Q.What is the material, resin and content? (Tool Wear Considerations)
A. Use aluminum horns with plating for unfilled materials. Use titanium horns for resins with fillers.
Q. What is the volume or duty cycle for the horn? A. If the project is low to moderate volume (less than 250,000/yr.), aluminum horns with plating are the best bet. As duty cycles and volumes increase, consider titanium for less maintenance.
A. If the project is low to moderate volume (less than 250,000/yr.), aluminum horns with plating are the best bet. As duty cycles and volumes increase, consider titanium for less maintenance.
Q. What is the physical size and shape of the part?
A. Large and irregularly shaped parts should use aluminum horns for machining considerations. Small to medium parts can use either aluminum or titanium.
Q. What is the price difference?
A. Important question. In many cases, more than one horn material will meet the needs of the application By considering the 3 previous questions along with the price difference an educated decision should be made.
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