1、AWS G1.1M/G1.1:2006An American National StandardGuide toUltrasonicAssembly ofThermoplastics550 N.W. LeJeune Road, Miami, FL 33126AWS G1.1M/G1.1:2006An American National StandardApproved by theAmerican National Standards InstituteJuly 6, 2006Guide toUltrasonic Assemblyof Thermoplastics1st EditionPrep
2、ared by theAmerican Welding Society (AWS) G1 Committee on Joining of Plastics and CompositesUnder the Direction of theAWS Technical Activities CommitteeApproved by theAWS Board of DirectorsAbstractThis guide details the ultrasonic equipment and the processes used in industry for fabricating thermopl
3、astic parts, includingwelding, staking, swaging, insertion, forming, degating, cutting, and trimming. Included are sections on safety, equipmentsetup, joint and part design, testing, and process optimization.iiAWS G1.1M/G1.1:2006International Standard Book Number: 0-87171-032-3American Welding Socie
4、ty550 N.W. LeJeune Road, Miami, FL 33126 2006 by American Welding SocietyAll rights reservedPrinted in the United States of AmericaPhotocopy Rights. No portion of this standard may be reproduced, stored in a retrieval system, or transmitted in anyform, including mechanical, photocopying, recording,
5、or otherwise, without the prior written permission of the copyrightowner.Authorization to photocopy items for internal, personal, or educational classroom use only or the internal, personal, oreducational classroom use only of specific clients is granted by the American Welding Society provided that
6、 the appropriatefee is paid to the Copyright Clearance Center, 222 Rosewood Drive, Danvers, MA 01923, tel: (978) 750-8400; Internet:.iiiAWS G1.1M/G1.1:2006Statement on the Use of American Welding Society StandardsAll standards (codes, specifications, recommended practices, methods, classifications,
7、and guides) of the AmericanWelding Society (AWS) are voluntary consensus standards that have been developed in accordance with the rules of theAmerican National Standards Institute (ANSI). When AWS American National Standards are either incorporated in, ormade part of, documents that are included in
8、 federal or state laws and regulations, or the regulations of other govern-mental bodies, their provisions carry the full legal authority of the statute. In such cases, any changes in those AWSstandards must be approved by the governmental body having statutory jurisdiction before they can become a
9、part ofthose laws and regulations. In all cases, these standards carry the full legal authority of the contract or other documentthat invokes the AWS standards. Where this contractual relationship exists, changes in or deviations from requirementsof an AWS standard must be by agreement between the c
10、ontracting parties.AWS American National Standards are developed through a consensus standards development process that bringstogether volunteers representing varied viewpoints and interests to achieve consensus. While AWS administers the processand establishes rules to promote fairness in the devel
11、opment of consensus, it does not independently test, evaluate, orverify the accuracy of any information or the soundness of any judgments contained in its standards.AWS disclaims liability for any injury to persons or to property, or other damages of any nature whatsoever, whetherspecial, indirect,
12、consequential or compensatory, directly or indirectly resulting from the publication, use of, or relianceon this standard. AWS also makes no guaranty or warranty as to the accuracy or completeness of any informationpublished herein.In issuing and making this standard available, AWS is not undertakin
13、g to render professional or other services for or onbehalf of any person or entity. Nor is AWS undertaking to perform any duty owed by any person or entity to someoneelse. Anyone using these documents should rely on his or her own independent judgment or, as appropriate, seek theadvice of a competen
14、t professional in determining the exercise of reasonable care in any given circumstances.This standard may be superseded by the issuance of new editions. Users should ensure that they have the latest edition.Publication of this standard does not authorize infringement of any patent or trade name. Us
15、ers of this standard acceptany and all liabilities for infringement of any patent or trade name items. AWS disclaims liability for the infringement ofany patent or product trade name resulting from the use of this standard.Finally, AWS does not monitor, police, or enforce compliance with this standa
16、rd, nor does it have the power to do so.On occasion, text, tables, or figures are printed incorrectly, constituting errata. Such errata, when discovered, are postedon the AWS web page (www.aws.org).Official interpretations of any of the technical requirements of this standard may only be obtained by
17、 sending a request,in writing, to the Managing Director, Technical Services Division, American Welding Society, 550 N.W. LeJeune Road,Miami, FL 33126 (see Annex A). With regard to technical inquiries made concerning AWS standards, oral opinionson AWS standards may be rendered. However, such opinions
18、 represent only the personal opinions of the particularindividuals giving them. These individuals do not speak on behalf of AWS, nor do these oral opinions constitute officialor unofficial opinions or interpretations of AWS. In addition, oral opinions are informal and should not be used as asubstitu
19、te for an official interpretation.This standard is subject to revision at any time by the AWS G1 Committee on Joining of Plastics and Composites. Itmust be reviewed every five years, and if not revised, it must be either reaffirmed or withdrawn. Comments (recommen-dations, additions, or deletions) a
20、nd any pertinent data that may be of use in improving this standard are requiredand should be addressed to AWS Headquarters. Such comments will receive careful consideration by the AWS G1Committee on Joining of Plastics and Composites and the author of the comments will be informed of the Committees
21、response to the comments. Guests are invited to attend all meetings of the AWS G1 Committee on Joining of Plasticsand Composites to express their comments verbally. Procedures for appeal of an adverse decision concerning all suchcomments are provided in the Rules of Operation of the Technical Activi
22、ties Committee. A copy of these Rules can beobtained from the American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126.This page is intentionally blank.ivAWS G1.1M/G1.1:2006vAWS G1.1M/G1.1:2006PersonnelAWS G1 Committee on Joining of Plastics and CompositesE. S. Stumpek, Chair E. Stumpek 2. I
23、nternal. The welding results from mechanicalmotion applied to the parts resulting in energy dissipa-tion and heating. Examples are ultrasonic, vibration, andspin welding; and3. Electromagnetic. The heat is generated by an elec-tric current or electromagnetic field passing through thepolymer joint in
24、terface. Examples are radio-frequency(r-f), microwave, and induction.The selection of a joining process depends on therequirements for the joint, the materials used, and thegeometry of the part or structure.1.3 Ultrasonic AssemblyIn this process, low-amplitude, high-frequency mechani-cal vibration (
25、ultrasonic energy) is used to soften or meltthermoplastic materials to effect blending, and uponcooling, a weld.Ultrasonic energy can also be used for insertion of metalcomponents into plastic parts, and to reform thermo-plastic studs or ridges to mechanically join parts usingGuide to Ultrasonic Ass
26、embly of Thermoplastics1. GeneralAWS G1.1M/G1.1:2006 GENERAL2staking or swaging processes. Ultrasonic vibration is alsoused to degate (separate) injection molded componentsfrom their runners.In each of these processes, the thermoplastic parts aresubjected to low-amplitude, high-frequency mechanicalv
27、ibrations. This energy is converted into heat withinthe thermoplastic through intermolecular friction, whichsoftens or melts the polymer. The processes of welding,insertion, staking, swaging, and degating use essentiallythe same equipment. The joint requirements, materialsand geometries determine wh
28、ich of these processes willbest meet the final assembly needs.1.4 Process DescriptionUltrasonic assembly is the joining or reforming of ther-moplastics using high-frequency vibrations to generateheat. For example, a metal object becomes warmer whenrepeatedly struck with a hammer. The kinetic energy
29、ofthe hammering transforms into thermal energy (heat) asthe molecules in the object move more vigorously. Thesemolecules are likewise excited to move vigorously whensubjected to the impact (hammering) of high-frequencyultrasonic vibrations.An ultrasonic welding system applies high-frequencyenergy (v
30、ibrations) through one part, focusing the energyinto the junction of the two parts. The focusing of theenergy is critical. The details of this method are pre-sented elsewhere in this document.1.5 System Component FunctionsThe basic assembly system consists of four majorcomponents:1. Power supply/gen
31、erator,2. Converter,3. Booster, and4. Horn.The power supply/generator converts commonly avail-able line voltage electrical power into high-frequencyelectrical energy. Although any frequency between 15 kHzand 70 kHz could be used, 20 kHz is the most popular.The converter changes the electrical energy
32、 into longitu-dinal (axial), low-amplitude mechanical vibrations of thesame frequency.The booster couples the mechanical vibrations from theconverter to the horn, and depending on its size andshape, can increase or decrease the amplitude of thesevibrations.The horn transmits the vibrational energy f
33、rom thebooster into the workpiece. The horn design is critical,since, like the booster, its size and shape affect the ampli-tude of the vibrations and consequently the heating of thethermoplastic parts.1.6 Systems for Applying Energy to WorkA press system is recommended for critical, preciselycontro
34、lled applications. When consistency and appear-ance are not critical, a hand-held unit may be adequate.Many manufacturers use compact actuators in applica-tions where an automated press system would be toolarge. These actuators offer press control in a smallerpackage that is better suited to custom
35、mounting. Whenproduction rates demand faster speeds than standardpress systems can provide, rotary index systems can beused. Fully automated systems are available for ultra-high-speed assembly operations.1.7 Process Advantages and Limitations1.7.1 Advantages. Ultrasonic assembly can have thefollowin
36、g advantages over other joining techniques:1. Uniform joining is achieved because heatingoccurs rapidly and is confined to the immediate jointarea;2. The weld strength can be as strong as the unrein-forced base material;3. No solvents, adhesives, or external heating arerequired;4. Dissimilar materia
37、ls can be assembled using ultra-sonic process; and5. Ultrasonic assembly is considerably faster thanother methods, resulting in higher efficiency and greatereconomy.1.7.2 Disadvantages1. Ultrasonic assembly equipment is moderatelyexpensive;2. Initial equipment and process setup can be compli-cated;
38、and3. Flash, particulates, and stresses occasionallyappear at the joint after welding.GENERAL AWS G1.1M/G1.1:200631.8 Safety and HealthUltrasonic assembly operations involve potentially haz-ardous equipment and materials. Personnel should betrained in the proper use of the equipment, and the safetya
39、nd health practices mandated by OSHA and local codes,and those recommended by the equipment and materialssuppliers. Proper work attire, including safety glassesand hearing protection, should be specified and enforced.Material safety data sheets (MSDSs) should be availableto personnel for all materia
40、ls and chemicals used in themanufacturing area. For additional help on improvingplant safety, consult ANSI Z49.1, Safety in Welding,Cutting, and Allied Processes, available from AmericanWelding Society. Some basic safety rules to observeinclude:1. Keep hands away from under the horn. An ener-gized h
41、orn in contact with skin can cause burns. Also, amoving horn can cause rapid, crushing forces;2. To prevent electrical hazards, verify all equipmentis electrically grounded, verify the power supply is OFFbefore making any electrical connections, and unplug thepower supply before removing its cover.
42、Never operatethe unit with the cover removed;3. Do not press the power supply TEST if either theRF cable or the converter is disconnected as this maycause potential damage to the generator;4. Verify no one is in contact with the horn when theTEST button is activated to prevent skin burns; and5. Use
43、hearing protection to prevent hearing loss ifthe operation is noisy.1.9 Units of MeasurementThis standard makes use of both International System ofUnits and U.S. Customary Units. The latter are shownwithin parentheses or in appropriate columns in tablesand figures. The measurements may not be exact
44、equiva-lents; therefore, each system shall be used independently.This page is intentionally blank.4AWS G1.1M/G1.1:20065AWS G1.1M/G1.1:2006The following standards contain provisions which,through reference in this text, constitute provisions ofthis AWS standard. For dated references, subsequentamendm
45、ents to, or revisions of, any of these publicationsdo not apply. However, parties to agreements based onthis AWS standard are encouraged to investigate thepossibility of applying the most recent editions of thedocuments shown below. For undated references, thelatest edition of the standard referred
46、to applies.1. ANSI Z49.1, Safety in Welding, Cutting, andAllied Processes12. ASTM D 256, Test Method for Determining theIzod Pendulum Impact Resistance of Notched Specimensof Plastics21. ANSI Z49.1 is published by the American Welding Society,550 N.W. LeJeune Road, Miami, FL 33126.2. ASTM standards
47、are published by the American Society forTesting and Materials, 100 Barr Harbor Drive, West Consho-hocken, PA 19428-2959.3. ASTM D 4065, Practice for Determining andReporting Dynamic Mechanical Properties of Plastics4. AWS A3.0, Standard Welding Terms andDefinitions35. AWS B2.4, AWS B2.4, Specificat
48、ion for Weld-ing Procedure and Performance Qualification forThermoplastics6. DIN 53455, Testing of Plastics Tensile Test47. DVS 2203, Testing of Welding Joints ofThermoplastics53. AWS standards are published by the American WeldingSociety, 550 N.W. LeJeune Road, Miami, FL 33126.4. Available from Deu
49、tsches Institut fr Normung e.V., 10772Berlin, Germany.5. Available from Deutscher Verband fr Schweien und ver-wandte Verfahren e.V. (German Welding Society), AachenerStr. 172, D-40223 Dsseldorf, Germany.2. Referenced DocumentsThis page is intentionally blank.6AWS G1.1M/G1.1:20067AWS G1.1M/G1.1:2006Plastics welding terms are defined in this section. Otherwelding terms used in this specification shall be inter-preted in accordance with the definitions given in thelatest edition of AWS 3.0, Standard Welding Terms andDefinitions.acoustical property. The ability of a material to transmitvibra
