Ideally, in ultrasonic welding the area where the horn contacts the part should be as close to the part joint as possible. However, at times, odd-shaped and sized parts prevent a half-wave horn from contacting the part where needed or developing sufficient amplitude to weld the application. In these situations, the answer is to use of a composite/compound horn.
What is a composite horn?
A composite horn is several individual horns (commonly referred to as “horn tips”) attached to a coupling horn to form a single, tuned, full-wavelength unit.
- Large coupling horn made from aluminum or titanium, as determined by the size and amplitude requirements of the application.
- Horn Tips – the individual “working horns” are made from either titanium or steel.
Benefits of using composite horns:
- Reduce internal horn stress by building higher amplitude on the horn tip. The amplitude at the face of a composite horn is substantially higher than what could be delivered by a single, large horn.
- Easily welds hard to reach weld areas. Composite horns have been used to solve the amplitude or wear problems encountered in large, multiple insertions, staking, and stud welding applications.
- Eliminates the need for multiple welders. They can provide greater part coverage, which in some cases can eliminate the need for multiple welders.
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