Plastic Assembly News

PLASTIC MATERIAL REFERENCE GUIDE FOR ULTRASONIC WELDING

The chart below includes recommended amplitudes for ultrasonic welding. These values are reference points for the required gain needed to weld the plastic material. The amplitude may need to be adjusted to achieve the best results for a particular application. (The amplitude level presented in the chart is displayed in microns-to convert to inches, 25.4 microns is equal to .001 of an inch)

Material Welding Insertion Staking Near Field Welding Far Field Welding Ease of Staking Trade name(s
AMORPHOUS RESINS
ABS-Acrylonitrile Butadiene 30-70 20-50 30-80   1 1 1 Cycolac, Lustran
Styrene                
                 
ABS/PC-ABS/Polycarbonate 70-100 50-70 80-120   2 2 2 Cycoloy,  Pulse
                 
ASA-Acrylonitrile Styrene 30-70 20-40 70-90   1 1 3 Centrex, Geloy, Luran
Acetate                
                 
PC-Polycarbonate 50-90 40-70 50-90   1 2 3 Lexan, Calibre, Novarex
                 
PEI-Polyetherimide 70-100 40-70     2 4 5 Ultem
                 
PES-Polyethersulfone 70-100 40-70     2 4 5  Ultrason
                 
PMMA-Acrylic 40-70 30-60 70-90   1 3 3 Acrylite, Plexiglass, Zylar
                 
PPO-Polyphenylene Oxide 50-90 40-60 60-90   2 3 2 Noryl
                 
PS-Polystyrene 20-40 20-40 70-90   1 1 4 Dylark,   Styron
                 
PSU-Polysulfone 70-100 40-70 90-120   2 3 3  Udel
                 
PVC-Polyvinyl Chloride (Rigid) 40-80 20-50 70-100   2 4 2 Novablend, Ultrachem
                 
SAN-Styrene Acrylonitrile 30-70 20-40 70-90   1 1 3 Lustran, Styvex
                 
SBC-Styrene Block Polymers 50-90 30-50 80-100   2 3 2  K-Resin
                 
SEMI-CRYSTALLINE RESINS
PA- Polyamide  (Nylon) 70-120 40-80 60-120   2 5 3 Celstran, Ultramid,  Zytel
                 
PBT-Polybutylene terephthalate  70-125 40-80 90-120   3 5 4 Celanex, Ultradur,  Valox
(Polyester)                
                 
PE-Polyethylene 70-120 40-80 40-120   2 5 2 Aspun, Clysar, Dowlex
                 
PEEK-polyetheretherketone 60-125 40-80     3 5 5 Arlon
                 
PET-Polyethylene terephthalate  80-120 40-80 90-120   3 5 4 Mylar, Rynite, Cleartuf
(Polyester)                
                 
PMP-Polymethylpentene 70-120 40-80 90-120   4 5 2 TPX
                 
POM- Polyacetal 75-125 40-80 50-100   2 3 4 Acetal, Celcon,   Delrin
                 
PP-Polypropylene 70-120 40-80 40-120   2 5 2 Astryn, Fortilene, Marlex
                 
PPS-Polyphenylene sulfide 80-125 40-80     3 4 5 Fortron, Ryton, Supec

 

Notes: 

   -Far and near field welder refers to the distance from the ultrasonic horn contact

            surface to the weld joint.  Generally, any distance in excess of 6.35 mm or .250″ is

            considered far field. 

  -The ease of welding and staking guide is rated from 1 to 5 with 1  

    equaling the easiest and 5 equaling the most difficult. 

 – The ability to weld plastic is based upon a lot of factors including joint design,    

    material fillers, process variables prior to welding, part geometry, good part design 

    practice, part size, amplitude, fixturing, properly designed ultrasonic horns and the 

    material flow during energy transfer. This chart displaying the ease of welding is meant to  

    serve as a guide only.

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