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100 articles

2026-09-09

Cold Welds: It Looks Joined, but Nothing Fused

Pressed together is not fused. A cold weld looks perfect and may survive a casual pull test, yet no molecular bond formed. How to detect and avoid it.

Welding Thin-Walled Parts: Punch-Through, Distortion and Resonance

Technical

2026-09-09

Welding Thin-Walled Parts: Punch-Through, Distortion and Resonance

Thin walls lack stiffness, so energy takes unintended paths: punch-through, collapse, or cracking far from the joint from the part resonating on its own.

Where Weld-Line Whitening and Haze Come From

Technical

2026-09-09

Where Weld-Line Whitening and Haze Come From

Whitening and haze are most visible on clear parts. Three distinct causes — stress whitening, micro-cracking from overheating, and re-crystallisation haze.

Technical

2026-09-09

Controlling Flash in Ultrasonic Welding

Flash means more melt than the joint can contain. Usually a joint design problem rather than a parameter one — director too tall, weld too deep, or no flash trap.

Hold Time: Why That Extra Second Cannot Be Skipped

Technical

2026-09-09

Hold Time: Why That Extra Second Cannot Be Skipped

When ultrasound stops the joint is still molten. Force during hold compensates for shrinkage as it solidifies. Releasing early leaves voids and locked-in stress.

Weld Force and Amplitude Work Against Each Other

Technical

2026-09-09

Weld Force and Amplitude Work Against Each Other

Force keeps the faces in contact; amplitude generates the friction that melts them. Too much force suppresses the vibration itself. Set amplitude first, then find the force.

Choosing the Trigger: Deciding When the Weld Starts Counting

Technical

2026-09-09

Choosing the Trigger: Deciding When the Weld Starts Counting

The trigger decides when ultrasound starts. An unstable start point puts every parameter on a drifting datum. Time, position, force and combined triggers compared.

Six Ultrasonic Weld Modes and When to Use Each

Technical

2026-09-09

Six Ultrasonic Weld Modes and When to Use Each

The weld mode decides what stops the weld. Time is simplest but compensates for nothing; energy is the general-purpose choice; depth modes control the finished dimension.

Why Medical Disposables Are Welded Rather Than Glued

Industry

2026-09-09

Why Medical Disposables Are Welded Rather Than Glued

Adhesive introduces a foreign substance, with residue, biocompatibility and cure control to manage. An ultrasonic weld is the parent material itself.

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