Section 9 - Troubleshooting

Welding Process

Material Choice

A family of thermoplastics is usually compatible with its own type and sometimes with other types. Characteristics to consider are the melting point and coefficient of linear expansion. Even members of the same family may cause problems due to differences in the manufacturing process. For example, an extruded Polyethylene (PE) piece may not weld as well to an injection molded PE piece as it would to another extruded PE piece.

Parameter Effects

Surface Speed

Insufficient surface speed may not allow the plastic to reach its melting temperature. Instead, it may simply erode away part of the material and stick by a clawing effect. The surface speed is determined by both the weld joint diameter and the spin motor speed.

Axial Speed

In conjunction with surface velocity, axial speed determines whether the plastic reaches the melting temperature. Both surface and axial speed are needed to produce sufficient frictional heating. Excessive axial speed may cause one part to scrape away part of the surface and produce a lot of flash but insufficient melt volume.

Weld Depth

Insufficient welding depth may not allow the melt to propagate far enough into the plastic to achieve the necessary melt volume and the required weld strength.

Hold Time

Insufficient holding time may prevent the plastic from solidifying and forming a strong permanent bond.

Troubleshooting

Table 9-I lists some potential problems with the weld process and suggested solutions.

Dukane Manual Part No. 403-570-01

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Dukane 403570-01 user manual Welding Process, Troubleshooting
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403570-01 specifications

The Dukane 403570-01 is a sophisticated ultrasonic welding machine renowned for its versatility and efficiency in various industrial applications. Designed with advanced technology, this model is favored in sectors such as automotive, medical, textiles, and consumer goods for its ability to provide consistent and reliable weld results.

One of the main features of the Dukane 403570-01 is its state-of-the-art ultrasonic transducer, which converts electrical energy into mechanical vibrations. This high-frequency sound wave technology allows for the joining of materials without the need for additional adhesives or fasteners, making it an environmentally friendly and cost-effective solution for manufacturers. The transducer operates at a frequency of 20 kHz, optimal for producing strong and durable welds.

In addition to its transducer, the 403570-01 is equipped with an advanced generator that provides precise control over the welding process. This generator adjusts the energy output based on the materials being welded and the specific application, ensuring optimal settings for each job. The machine also features a user-friendly control panel that allows operators to easily program and monitor welding parameters such as time, power, and pressure.

The 403570-01 is designed for ease of use and maintenance. Its modular design simplifies servicing and allows for quick replacement of components, ensuring minimum downtime. Additionally, the machine’s lightweight construction enhances portability, making it suitable for both dedicated production lines and on-the-spot repairs.

Another significant characteristic of the Dukane 403570-01 is its versatility in handling various materials, including plastics, metals, and composites. This flexibility opens up a wide array of welding applications, from assembling intricate medical devices to automotive components. Furthermore, it features integrated safety measures that protect both the operator and the machine, reducing the risk of accidents during operation.

In summary, the Dukane 403570-01 stands out due to its advanced ultrasonic technology, user-friendly controls, and versatility in handling various materials. With its robust design and efficient welding capabilities, it is an invaluable asset for manufacturers looking to enhance their production processes and maintain high-quality standards.
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