Ultrasonic Welding Stack
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Ultrasonic Welding Stack
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AFM Engineering> Ultrasonic Welding> Ultrasonic Welding Information> About Ultrasonic Welding> Ultrasonic Welding Stack
Ultrasonic Welding Stack Assembly
Stack Assembly
Stack Assembly		 The Ultrasonic Stack Assembly consist of Convertor, Booster, Horn and two studs. To tune properly the stack needs to appear to be one solid pike of material. Any one part of the stack that is loose or has a crack in it will make the stack not tune properly, usually making the welding machine overload.

If your welding machine is overloading while attempting to test the Ultrasonic's do the following:

1. Remove the stack from the welder.
2. Using a Bench Vice or Spanner Wrench remove the horn.
3. Using a Allen Wrench and Bench Vice or Spanner Wrench remove the Horn Stud.
4. Examine the Horn Stud for stress cracks.
5. Using a Bench Vice or Spanner Wrenches remove the Booster from the Convertor.
3. Using a Allen Wrench and Bench Vice or Spanner Wrench remove the Booster Stud.
4. Examine the Booster Stud for stress cracks.
6. Examine the Horn for stress cracks.
7. Examine the Booster for stress cracks.
8. Examine the Convertor for stress cracks. Shake the Convertor. If it rattles the crystals have broken and it must be rebuilt or replaced.

If everything appears to be OK start to reassemble the Stack:
1. Clean any debris from the Convertor output.
2. Clean and debris from the Booster Input and Stud Hole.
3. Insert the Booster Stud into the Booster. Using a Allen Wench and a Bench Vice or Spanner Wench tighten the Stud into the Booster.
4. Screw the Convertor onto the Booster.  Using tools tighten the Booster to Convertor.
5. Clean any debris from the Booster Output.
6. Clean any debris from the Horn Input and Stud Hole.
7. Screw the Horn Stud into the Horn. Using tools tighten the Stud to Horn.
8. Screw the Horn onto the Booster. Using tools tighten the Horn onto the Booster.
Put the Stack back into the welding machine.  Use the machine Test Button to see of the stack will tune.

Stack Assembly Tightening Information

Studs in horns and boosters:

12-18 in.-lb 1-1.5 ft.- lb 1/2 X 20 studs
12-18 in.-lb 1-1.5 ft.- lb 3/8 X 24 studs
12-18 in.-lb 1-1.5 ft.- lb 8 mm studs

Transducer/booster/horn assembly:

540 in.- lb 45 ft.- lb 15 kHz Stack
420 in.- lb 35 ft.- lb 20kHz Stack
216 in.- lb 18 ft.- lb 40 kHz Stack
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