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Is Ultrasonic Welding The Same As Vibration Welding?

It is often misunderstood that ultrasonic welding and vibration welding are the same welding process because they both use vibrational energy to weld plastic components. In fact, the implementation process of these two welding methods is completely different. Let’s take a look at the differences between the two.

Difference 1: Vibration Mode

Vibration welding is a friction welding process. It emits pressure to move two materials relative to each other on a horizontal plane to melt and weld. Ultrasonic welding conducts ultrasonic waves to the welding head, it has longitudinal and torsional technology.

ultrasonic welding VS vibration welding
Frequency

Difference 2: Vibration Frequency

The vibration welding process vibrates at approximately 120-240Hz per second, depending on the size of the parts being welded. This frequency is in the range of human hearing, so vibrating equipment uses sound enclosures to protect machine operators from deafening fog-horn-like sound.
Most ultrasonic welding processes operate between 20 and 40 kHz frequency, some work at 15 kHz, which is technically outside the ultrasonic range, but is still considered ultrasonic welding. Ultrasonic welding at 20-40 kHz is quieter than vibration welding but does sometimes produce harsh sounds due to the lower resonant frequency of plastic parts.

Difference 3: Welding Time

Vibration welding is a very fast process, with typical cycle times in the range of 5-10 seconds, ultrasonic welding is faster than vibration welding, with typical cycle times between 1 and 3 seconds.

welding time
Is Ultrasonic Welding The Same As Vibration Welding

Difference 4: Welding Principle

Vibration welding produces high-temperature melting by causing relative motion between plastics, leaving flash after solidification.
Ultrasonic welding emits high-frequency ultrasonic vibrations between plastics. The plastic melts at high temperatures, forming new molecular bonds with smaller traces.

Difference 5: Welding Object

Due to the large welding pressure and lateral force, vibration welding is not suitable for welding sensitive components or smaller products. Ultrasonic welding can choose machines with different frequencies according to different products to complete a wider range of welding.

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