Table of Contents

1. Introduction to ultrasonic rotary welding
2. Applications of Ultrasonic Rotary Welding
3. Technical Parameters in Ultrasonic Rotary Welding
4. Powersonic Company Solutions
5. References

Introduction to Ultrasonic Rotary Welding

Ultrasonic rotary welding is a specialized technique for joining materials using high-frequency ultrasonic vibrations combined with pressure. This method is especially effective for materials with high melting points or where adhesive or other bonding methods are unsuitable.

Unlike conventional ultrasonic welding, rotary welding involves circular motion, which allows for continuous welding in applications such as tubing or circular seams. This makes it particularly useful in industries where speed and precision are crucial, such as automotive, medical devices, and filtration.

Applications of Ultrasonic Rotary Welding

Ultrasonic rotary welding finds its utility in a variety of sectors, including:

• Automotive Industry: Used for welding parts like fuel filters, sensors, and even fabric-based components.
• Medical Device Manufacturing: Essential for producing sterile, accurate welds in items like IV catheters and filter membranes without adding contaminants.
• Textile and Nonwoven Fabrics: Provides a seamless bond in garments, disposable wear, and technical textiles without altering material characteristics.
• Packaging: Provides airtight seals in pouches and flexible packaging materials, ensuring product safety and longevity.

Technical Parameters in Ultrasonic Rotary Welding

Successful ultrasonic rotary welding depends on various parameters which must be meticulously controlled:

• Frequency: Commonly ranges from 20 kHz to 70 kHz. The choice of frequency depends on the material type and thickness.
• Amplitude: Typically varies from 10 to 50 micrometers, determining the energy delivered to the welding interface.
• Pressure: Must be optimized to ensure a proper bond without damaging the materials. Typical pressures range from 20 to 150 N/cm².
• Welding Speed: Influences the efficiency and quality of the welding process. Speeds can range from 2 to 20 meters per minute.

Powersonic Company Solutions

Powersonic specializes in delivering advanced ultrasonic welding solutions tailored to industry-specific needs. Their offerings in rotary welding systems include:

• Customizable Systems: Powersonic provides systems that can be tailored to specific application requirements, ensuring precise control over welding parameters.
• High-Precision Equipment: Designed to meet stringent industry standards, ensuring reliability and repeatability in production environments.
• Comprehensive Support: From initial planning to implementation and maintenance, Powersonic offers extensive support to ensure seamless integration of their ultrasonic welding solutions.

References

1. K. Brinkman and T. Flottmann, Advancements in Ultrasonic Welding: Materials, Techniques, and Applications, International Journal of Welding Technology, vol. 45, no. 3, pp. 210-224, 2023.
2. Powersonic Ultrasonic Solutions. Product Brochure: Rotary Welding Systems, 2023. Available: www.powersonic.com/products/rotary-welding.
3. J. Hargrave, Innovations in Welding Technologies for the Automotive Sector, Automotive Welding Journal, vol. 22, pp. 67-81, 2022.