Before talking about the factors that affect the service life of ultrasonic welding horns in detail, I think we need to first understand the specific functions of welding horns in ultrasonic welding.
In one sentence: the welding horn is a tool that effectively transmits vibration to the plastic welding part.
Simply put, the welding horn has the function of transmitting vibration energy, pressure and amplitude. It needs to provide a shape consistent with the shape of the product, and because the plastic is malleable, it can fit the product to a certain extent.

4 factors affecting the service life of ultrasonic welding horn:

①Material and material of welding horns:
There are three commonly used materials for making welding horns: aluminum alloy, titanium alloy and alloy steel. Each material has its own unique properties, and different materials will lead to different service lives.
Aluminum alloy is used in the soft mold verification process stage or small batch production stage and cannot withstand mechanical stress. or for large welding horns where weight and cost are important considerations.

Titanium alloy is used in the small, medium and large-volume production stages of products. It has excellent acoustic properties, can withstand the maximum mechanical stress three times that of aluminum alloy, and has relatively excellent wear resistance.
Alloy steel is used for welding plastic parts where aluminum alloys and titanium alloys cannot be used. It has high hardness and the highest wear resistance, and generally needs to be hardened before use.

②Welding process requirements:
Common ultrasonic welding horns generally have two sides, but they can also be made into four or six sides. The welding area depends on the production process.
For example, some are welded to the tabs of small cylindrical batteries, and some are welded to the tabs of soft-packed batteries. Judging from the two welding processes, the service life of the half-wave welding horn is longer than that of the full-wave welding horn. There are also process requirements such as copper to copper welding, aluminum to aluminum welding, copper clad aluminum, aluminum to nickel, nickel to nickel, etc., which will affect the service life of the welding horn.

③ Parameters during welding:
During the working process of the ultrasonic welding machine, if the welding current is large, the frequency is high, the time is long, and the temperature is high, the life of the welding head will be shortened accordingly.

④Material and thickness of welding material:
Ultrasonic metal welding usually welds copper and aluminum, and the life of the welding horn is lower when welding copper than when welding aluminum.

The above are just some examples, welcome to consult online, Lingke Ultrasonics will professionally analyze the suitable equipment model for you, and match you with the most suitable welding head to present the most perfect welding effect!