Ultrasonic 

Metal-Weld Horns

The ultrasonic metal weld horn, sometimes called a sonotrode, is an acoustic tool designed to perform work at a selected resonant frequency. The resonant frequency is determined by the composition, physical shape and working temperature of the tool.

The horn has two main purposes in an ultrasonic metal weld system. First, the horn transfers the ultrasonic vibrations to the parts that are to be welded (weldment). Second, the horn is part of a clamping mechanism that provides a force on the weldment in a direction perpendicular to the vibrations.

Combined, the vibrations and clamping establish shear forces on the weldment interface required for an ultrasonic metal weld. Horns are a vital part of the welding system and are designed and fabricated for a specific application. 

The horn vibrates by expanding and contracting at a predetermined frequency - 20 kHz and 40 kHz being most common. The source of the vibration is the systems piezoelectric transducer (converter). 

Ultrasonic vibrations from the transducer are propagated through the horn as reciprocating compressional energy, which alternately expands and contracts the metal and establishes a harmonic wave. The peak-to-peak displacement, usually measured at the face of the horn, is referred to as amplitude.

More Information   Horn Design & Operational Care