Create Config
Edit Name Description Configuration Type Type

What is Vibration Welding?

Linear vibration welding physically moves one of two parts horizontally under pressure, creating heat through surface friction that melts and welds the parts together. Compared to ultrasonic welding, vibration welders operate at much lower frequencies, higher amplitudes and much greater clamping force. Linear vibration welding is designed with electromagnetic heads that eliminate the wear and lubrication associated with bearing surfaces.

View Vibration Welding Products

Vibration Welding Process

Play Video

Vibration Welding Stages

Vibration Welding Stages
  1. Linear motion of one part against another generates friction between the two surfaces, producing heat at the joint.
  2. The parts begin to melt at the joint. High heat generation from the high shear rate causes further melting and a thicker melt layer. As the melted layer thickens, the viscosity increases and the shear rate decreases resulting in less heating. Pressure on melting parts promotes fluid flow to create the joint.
  3. The weld process is discontinued when the joint has reached its optimum strength. This is indicated when the parts melt at a rate equal to the outward flow rate at the joint.
  4. With pressure maintained on the joint, the material re-solidifies, forming a molecular bond.

Advantages of Vibration Welding

  • Fast weld times (20 seconds part to part)
  • Power efficient (green machine)
  • Reusable resource (12 to 16 years of use)
  • Quick change tooling (can run multiple parts)
  • No marking of show surfaces
  • Accurate part to part dimensional
  • Strong Welds
  • Hermetic seals
  • 2D weld planes achievable

Material Considerations

Vibration welding can join all known thermoplastics including materials with up to 45 percent filler content. Vibration welders can also join many dissimilar materials with compatible melting points, composite materials and fabrics. The following materials may be assembled by vibration welders: amorphous resins such as ABS/PC, PVC, PMMA or PES; semi-crystallines such as HDPE, PA, PP and TEO. Vibration welders can also join fiber reinforced carriers such as wood fiber, textile fiber or Polyurethane Long Fiber directly or by claw effect, or with composite surface coating. Contact Dukane for details.

Download Material Compatibility Guide

Application Considerations

Dukane vibration welders are ideal in automotive assembly applications such as door panels, intake manifolds, instrument panels, tail lights and lenses, fluid reservoirs and bumpers. Aviation applications include HVAC ducts, air diverter valves, interior lighting and overhead storage bins. Appliance manufacturers may use Dukane vibration welders for dishwasher pumps and spray arms, detergent dispensers and vacuum cleaner housings. Accessories applications are business and consumer toner cartridges, point-of-purchase displays, display stands and shelves. Vibration welders may also assemble chainsaw housings and power tools. Medical applications include surgical instruments, filters and I-V units, bedpans and insulated trays.

Download Process Comparison Guide