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.
