iQ Series, Ultrasonic Hand Held Systems User’s Manual
Welding Problems
Weak Welds
Weak welds, or underwelding, is caused by insufficient energy being transmitted to the part. You can increase the weld pressure, increase the weld duration (Time or Energy) or change to a higher gain booster to increase the amplitude to increase the energy delivered to the weld.
Inconsistent Welds
Variations in plastic due to filler materials and moisture absorption may lead to inconsistent welds. Fillers can be especially troublesome if they are not uniformly distributed, the content is too high or it contains too much or poor quality regrind or degraded plastic.
Try welding by energy. This eliminates many inconsistencies.There should be no unusual or loud noise from the acoustic stack. If there is, disassemble the stack and reassemble.
Exchange the probe with another unit to see if the problem disappears. If not, exchange the generator with another unit to try and isolate the problem.
The horn amplitude may not be uniform if it has been machined, altered or damaged. All of these will change the resonant frequency of the horn. You can have the horn analyzed.
NOTE
Primary factors in achieving consis- tent, quality welds - especially when using hand held probes - are the skill and training of the operator.
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