Ultrasonic welding of PC + 20%GF (Lexan 3412) & PC Lexan 141R

[sizzer33]

HI fellow experts,

Just wanted to know if anyone had experience in doing ultrasonic welding between PC+20%GF material and PC. Just that we've been advised by horn manufacturer that there might be issues with welding Lexan 3412 material.

If possible, please advise what sort of problems encountered and if you manage to weld the part, what sort of parameter you use to control part defects in production.

thanks

 

[patprimmer]

I have seen 10% GF Polycarbonate ultrasonically welded to 10% GF polycarbonate, no problem. Glass filled materials are more difficult than unfilled due to there tendency to alow the resin to flow away, leaving a glass rich area, but this can be controlled to give a satisfactory weld with good part and horn design.

Regards

eng-tips, by professional engineers for professional engineers
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[Demon3]

I have seen 40% glass fiber in nylon 6 welded using vibrational welding with good strength. Same principal as ultrasonic welding just different frequency and amplitude.Your success may vary depending upon the fiber orientation relative to the weld plane though.

There is not any memory with less satisfaction than the memory of some temptation we resisted.
- James Branch Cabell

 

[patprimmer]

Demon3 is correct.

I have seen high glass content nylon 6 ultrasonic or vibration welded in a structural part of floating winch handles for yachts. It was the base or 4th side of the main beam of the handle, converting the channel section into a box section. They used between 25 and 45% depending on the length and grip design of the handle. This is made for Lewmar and was previously Titan. It markets under several brand names.

I have also seen 35% glass filled nylon 66 in the body of a steam iron with an integrated water tank. This was developed by Sunbeam in Australia in the late 70s and sold throughout the 80s.

Regards

eng-tips, by professional engineers for professional engineers
Please see FAQ731-376 for tips on how to make the best use of Eng-Tips Fora.

 

[Demon3]

I tell you what looked really cool. We vibration welded that nylon onto wood. It was a surprisingly strong joint, probably because nylon is very polar and so is the cellulose in the wood.

There is not any memory with less satisfaction than the memory of some temptation we resisted.
- James Branch Cabell

 

[sizzer33]

Thanks all.

Your replies gave me the confidence to convince the engineers to try out before complaining. Turns out the welding looks good and strong.