Types of welds used in ultrasonic welding

Close Welding
Ultrasonic welding where the horn is positioned near (<6.35mm) the assembly joint. This approach is particularly suitable for welding materials with a low rigidity modulus, which can dampen vibrations shortly after they move away from the horn.

Distant Welding
Ultrasonic welding where the horn is placed further away from (>6.35mm) the assembly joint. It proves effective for welding materials with a high modulus of elasticity. These materials are capable of transmitting vibrations without significant dampening.

Inserting
Ultrasonic inserting is used to incorporate metal components, such as inserts, into pre-made holes in the moulding. This method offers several advantages, including high strength and speed, prevention of stress accumulation, and shortened moulding cycles.

Spot Welding
The ultrasonic spot welding process is effective for joining parts that don't have pre-existing holes or energy directors - it's beneficial when dealing with larger components.

Staking
Melting and reforming a post on the moulding to mechanically lock dissimilar materials in place - provides short cycles, good appearance & tight assemblies.