1、Specificationfor StandardizedUltrasonic WeldingTest Specimen forThermoplasticsAWS G1.2M/G1.2:1999 (R2010)An American National Standard550 N.W. LeJeune Road, Miami, FL 33126AWS G1.2M/G1.2:1999 (R2010)An American National StandardApproved by theAmerican National Standards InstituteAugust 31, 1999Reaff
2、irmed: November 20, 2009Specification for StandardizedUltrasonic Welding TestSpecimen for Thermoplastics1st EditionPrepared by theAmerican Welding Society (AWS) G1 Committee on Joining of Plastics and CompositesUnder the Direction of theAWS Technical Activities CommitteeApproved by theAWS Board of D
3、irectorsAbstractThis specification outlines the requirements for the ultrasonic welding test sample for thermoplastics and its weldingand testing. In order to minimize variations, the geometry for the standard test sample is defined in detailed figures in-cluding tolerances on critical dimensions th
4、at may affect its weldability.This specification can be used for but not be limited to the following investigations:Thermoplastic Ultrasonic Weldability Studies;Thermoplastic Ultrasonic Welding Optimizations; andScientific Studies on the Ultrasonic Welding of Thermoplastics.Data collection of weldin
5、g variables is divided into three levels. Level three data recording requires the highest preci-sion of data collection and, consequently, is the most time intensive. Level two data recording requires moderate datacollection for more practical investigations. Level one data recording is the least st
6、ringent. These three levels are in-cluded in order to recognize the varying levels of precision required within the plastic welding community.AWS G1.2M/G1.2:1999 (R2010)iiInternational Standard Book Number: 0-87171-585-6American Welding Society550 N.W. LeJeune Road, Miami, FL 33126 1999 by American
7、Welding SocietyAll rights reservedPrinted in the United States of AmericaReaffirmed: November 20, 2009Photocopy Rights. No portion of this standard may be reproduced, stored in a retrieval system, or transmitted in anyform, including mechanical, photocopying, recording, or otherwise, without the pri
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9、o the Copyright Clearance Center, 222 Rosewood Drive, Danvers, MA 01923, tel: (978) 750-8400; Internet:.iiiAWS G1.2M/G1.2:1999 (R2010)Statement on the Use of American Welding Society StandardsAll standards (codes, specifications, recommended practices, methods, classifications, and guides) of the Am
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21、Services Division, 550 N.W. LeJeune Road, Miami, FL 33126 (see Annex D).With regard to technical inquiries made concerning AWS standards, oral opinions on AWS standards may be rendered.These opinions are offered solely as a convenience to users of this standard, and they do not constitute profession
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23、ot be used as a substitute for an official interpretation.This standard is subject to revision at any time by the AWS Committee on Joining of Plastics and Composites. It must bereviewed every five years, and if not revised, it must be either reaffirmed or withdrawn. Comments (recommendations,additio
24、ns, or deletions) and any pertinent data that may be of use in improving this standard are required and should beaddressed to AWS Headquarters. Such comments will receive careful consideration by the AWS Committee on Joiningof Plastics and Composites and the author of the comments will be informed o
25、f the Committees response to the com-ments. Guests are invited to attend all meetings of the AWS Committee on Joining of Plastics and Composites to expresstheir comments verbally. Procedures for appeal of an adverse decision concerning all such comments are provided in theRules of Operation of the T
26、echnical Activities Committee. A copy of these Rules can be obtained from the AmericanWelding Society, 550 N.W. LeJeune Road, Miami, FL 33126.This page is intentionally blank.ivAWS G1.2M/G1.2:1999 (R2010)vAWS G1.2M/G1.2:1999 (R2010)Personnel (Reaffirmation)AWS G1 Committee on Joining of Plastics and
27、 CompositesH. L. Mikeworth, Chair H. Mikeworth the word should denotes a guideline orrecommendation; and the word may denotes a choice.1.3 This standard makes use of both the InternationalSystem of Units (SI) and U.S. Customary Units. Themeasurements are not exact equivalents; therefore eachsystem m
28、ust be used independently of the other withoutcombining in any way. The standard with the designationG1.2M:1999 uses SI Units. The standard with the desig-nation G1.2:1999 uses U.S. Customary Units. The latterare shown in appropriate columns in tables and figures,and within parentheses ( ) when used
29、 in the text.2. Referenced DocumentsAWS G1.1 Guide to the Ultrasonic Assembly ofThermoplastics3. Definitionsactuator. The unit that houses the converter, booster, andhorn assembly in a rigid mounting allowing it to moveup and down either mechanically or pneumatically toapply a predetermined pressure
30、 on the workpiece.amplitude. The peak to peak displacement of the horn atits work face as expressed in m or in.booster. A one-half wavelength long resonant metal sec-tion mounted between the converter and horn, it mayhave a change in cross-sectional area between theinput and output surfaces. It usua
31、lly mechanically in-creases or decreases the amplitude of the system, oracts as a coupling bar.conditioned. Any condition other than dry-as-molded(i.e., moistened, aged, annealed, etc.).converter. An electro-mechanical device which trans-forms electrical energy to mechanical energy.coupling bar. A b
32、ooster with unity gain, i.e., does notchange the amplitude (1:1 Gain Ratio).displacement. The total collapse of the part during thewelding process, expressed in mm or in.down speed. The rate of travel of the actuator from thehome position to the part. Expressed in mm/s or in./s.dry-as-molded. The mo
33、isture condition of the test sam-ple as it is ejected from the mold.energy. In welding, energy required to melt the plasticequals the power delivered multiplied by the timepower is applied. Measured in watt seconds or joules.energy director butt joint. A joint that contains a trian-gular-shaped proj
34、ection of plastic material at the jointinterface of a plastic part that concentrates the ultra-sonic energy against a flat surface (see Figure 5).far field welding. Configuration where the joint surfaceplane is typically more than 6 mm (0.25 in.) from theplane of horn contact with the workpiece.fixt
35、ure. A device for locating and supporting the work-piece in position for assembly.flash. Material displaced from the joint area as a result ofwelding.frequency. The number of complete oscillations per sec-ond, or cycles produced by the converter, booster, andhorn. Expressed in Hertz (Hz) or kilohert
36、z (kHz).Specification for Standardized Ultrasonic WeldingTest Specimen for ThermoplasticsAWS G1.2M/G1.2:1999 (R2010)2gain. The relationship of masses on either side of thenodal point of a horn or booster.hold time. The length of time clamping force is main-tained on the workpiece after ultrasonics h
37、as stoppedto allow the plastic to solidify, expressed in seconds.horn. Usually a one-half wavelength long bar or metal sec-tion which transfers vibratory energy to the workpiece.joint interface. The weld contact surface of two matingparts.loading. The percent of power drawn from the powersupply duri
38、ng the ultrasonic process.near field welding. Configuration where the joint sur-face plane is typically less than 6 mm (0.25 in.) fromthe plane of horn contact with the workpiece.node/nodal point. Point or plane in acoustic tooling,such as converter, booster or horn, where the mechan-ical amplitude
39、in the direction of sound transmissionis at minimum.power control. A device used with a power supply orwelder to control the amplitude at the horn face.preloading. Application of a preset load on a part priorto triggering ultrasonics.pretriggering. Initiation of ultrasonics before the horncontacts t
40、he workpiece.ramp profile. The time and transition profile to reachdesired amplitude.shear joint. A joint design that utilizes a dimensional in-terference between the mating parts to accomplish aweld (see Figure 6).sonotrode. See horn.stack. An assembly consisting of the horn, booster, andconverter.
41、thermoplastics. Polymers that can be repeatedly meltedand resolidified by heating and cooling making themsuitable for ultrasonic welding.ultrasonic welding. Using ultrasonic vibrations to gen-erate heat and cause melting and blending at themating surfaces of two thermoplastic parts. When theultrason
42、ic vibrations stop, the molten material solidi-fies and a weld is achieved.welding cycle. Time from initial descent of the horn toretraction of the horn to home position. This includesweld and hold times.weld time. The length of time ultrasonic energy isapplied to the workpiece. Expressed in seconds
43、 ormilliseconds.workpiece. Item being welded by ultrasonics.4. SafetyAll ultrasonic bench top welding units comply withappropriate OSHA requirements. If handgun type equip-ment or automation is used, please review specific manu-facturer safety information before usage. However, thefollowing safety p
44、rocedures should be followed whensetting up, operating, or servicing any unit.(1) Keep hands away from under the horn. Downforce (pressure) can cause injury.(2) Be sure that no one is in direct contact with thehorn when the ultrasonic energy is activated. Ultrasonicvibrations can cause injury.(3) To
45、 prevent the possibility of an electrical shockand personal injury, always plug the power supply into agrounded plug source.(4) To prevent the possibility of an electric shock andpersonal injury, be sure the power supply is in the OFFposition before making any electrical connections.(5) To prevent t
46、he possibility of an electric shock andpersonal injury, be sure the unit is unplugged before re-moving the power supply and/or actuator cover.(6) To prevent the possibility of an electric shock andpersonal injury, do not operate the unit with the cover re-moved. High voltage is present in the power
47、supply.(7) To prevent the possibility of an electric shock andpersonal injury, do not press the TEST switch on thepower supply if either the RF cable or the converter isdisconnected.(8) Some plastic parts may vibrate within the audiblefrequency range when welded. If this occurs and discom-fort is pr
48、esent for the operator, use hearing protection toprevent possible injury.5. Geometry of the Standard Sample and Preparation5.1 Geometry Types. Four different geometries may betested:(1) Small energy director butt joint(2) Large energy director butt joint(3) Double shear joint(4) Reference sampleThes
49、e geometries are detailed in Figures 1 through 4.5.2 Mold Design. The samples shall be injectionmolded with all important molding parameters beingrecorded. It is recommended that the mold include thefollowing:(1) Uniform temperature distribution(2) Edge gate into one end away from weld area(3) All joining surfaces be free of ejector pins(4) Reference sample has similar flow to weldedsamplesAWS G1.2M/G1.2:1999 (R2010)35.3 Molded Sample Specification. The molded samplesshall have the following specifications:(1) Flatness including sink marks and warpage not toexceed 0.20 mm (0.008 in.). It is
