Tips on selecting Horns:
1. Know the welding amplitude requirements for your application.
2. Insure the horn design applies even amplitude and pressure over the work area.
3. Factor in amplitude loading. Use the analogy of trying to keep the horn vibrating while locked in a vice. In air amplitude and under load amplitude are two different things and even the most sophisticated welders can't change the physical effects. Large parts and welding at high pressures result in significant drops in amplitude, as much as 25%. Typical values are 5% - 15%.
4. Prototype applications to determine the optimum horn design and welding amplitude.
5. Use larger horn face dimensions than the actual part welding dimensions, whenever possible. Percentage of horn face loading greatly influences amplitude loading and peak power draw. Try to avoid loading 100% of the horn face.
6. Use aluminum horns with coatings whenever wear or fracture are not the major factors.
7. If experiencing stress fractures (cracks) with aluminum horns, switch to titanium.
8. Use titanium horns when welding glass, mineral, talc and carbon filled materials.
9. Use titanium horns for high amplitude applications, where welding amplitude is greater than .0036".
10. Use horns with replaceable tips for insertion, staking and spot welding applications. Helps control costs and quality.
11. Only use hardened tool steel horns for high wear, low amplitude applications. Steel is not a good choice when higher amplitude is required.
12. Purchase spare horn(s) whenever medium to high wear is expected. Horns are rarely stock items and down time will be excessive.
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