Ultrasonic Welding Transducer

Ultrasonic Welding Transducer

With high energy efficiency, wide frequency adaptability, and industrial-grade reliability, this transducer delivers precise welding solutions for electronics, automotive, and medical industries, empowering high-quality production and process innovation.

Structural Design

● Modular Stack Design: Prestressed bolts secure piezoelectric ceramic plates to titanium alloy horns, ensuring efficient high-frequency energy transfer with minimal loss.

● Precision Frequency Matching: Full series covers 14.8kHz–34.8kHz (e.g., DC-6015-8A4: 14.8kHz; DC-2535-8A2: 34.8kHz), adaptable to material thickness and welding strength requirements.

● Compact Packaging: Diameter 25mm–60mm, height 70mm–163mm, lightweight design for automated production line integration and rapid tooling changes.

● Thermal Management: Integrated cooling fins or forced-air cooling for high-power models (e.g., 2600W) to control temperature rise during continuous operation.

Material Properties

● High-Performance Piezoelectric Ceramic: Low-loss lead zirconate titanate (PZT) with static capacitance 1900pF–18,000pF (e.g., DC-5020-8S6: 17,000pF), electromechanical coupling coefficient (Kt) >60%, and energy conversion efficiency >90%.

● Titanium Alloy Horn: High fatigue resistance, wear resistance, and frequency stability, compatible with high-frequency (34.8kHz) and large-amplitude output.

● Coated Electrodes: Silver-nickel composite electrodes resist oxidation and arcing, ensuring electrical stability under prolonged high-frequency driving.

Core Advantages

● High Power Density: Max output 2600W (e.g., DC-6015-8A4) for welding engineering plastics (ABS, nylon) up to 6mm thick.

● Wide Frequency Adaptability:

 ○ Low-Frequency Models (14.8kHz–20kHz): Metal welding and large components.

 ○ High-Frequency Models (27.8kHz–34.8kHz): Precision electronics and ultra-thin materials.

● Extended Lifespan: <5% amplitude attenuation after million-cycle testing, supporting 24/7 operation.

● Plug-and-Play: Resonant impedance ≤10Ω (e.g., DC-5020-8S6) for seamless integration with standard ultrasonic generators, reducing setup time by 50%.

Typical Applications

● Electronics: Lithium battery tab welding, chip packaging, micro-sensor assembly (e.g., DC-3828-8A4 high-precision models).

● Automotive: Wire harness terminal welding, interior component fusion (e.g., DC-6015 series, 2600W high-penetration power).

● Medical Consumables: Catheter joint welding, sterile packaging sealing (e.g., DC-2535-8A2, HAZ <0.1mm).

● Packaging: PET cap sealing, food container closure (e.g., DC-5020 series, compatible with thermoplastics).

Core Guarantees

● Full-Process QC: Ensures amplitude consistency (±5%) and frequency deviation ≤0.3kHz through ceramic sintering, frequency matching, and aging tests.

● Custom Development: Tailored horn length, flange interfaces, and power levels (e.g., DC-5020-8H4 custom impedance design).

● Lifecycle Support: Vibration modal analysis, tooling design optimization, and on-site debugging for rapid deployment.