Prediction of Ultrasonic Welding Parameters for Polymer Joining

Process development and parameter optimization is a time-consuming and expensive effort, particularly due to the need for extensive testing of development samples, which can include lengthy fatigue testing and the destruction of hundreds or thousands of assemblies to validate a process. To improve the speed of process development, using theory to predict optimum welding parameters is a valuable approach to conserve material and labor resources.

Effective welding requires that the molten polymer chains at the joint surface diffuse across the joint and become entangled with polymer chains in the parts to be welded. This intermolecular diffusion and chain entanglement are the fundamental characteristics of welding. By using the first principles of heat generation and melt flow, optimal weld parameters can be calculated to ensure that diffusion across the weld joint occurs during ultrasonic welding.