Prediction of Ultrasonic Welding Parameters for Polymer Joining

Welding of polymers is a useful assembly process that eliminates the need for adhesives or mechanical fasteners, saving consumable costs. One of the most common polymer welding processes is ultrasonic welding. Effective welding requires that the molten polymer chains at the joint surface diffuse across the joint and become entangled with polymer chains in the parts to be welded. This intermolecular diffusion and chain entanglement are the fundamental characteristics of welding. Using fundamental theories of heat generation and melt flow, optimal weld parameters can be calculated to ensure that diffusion across the weld joint occurs during ultrasonic welding.