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What’s ultrasonic booster?

The Ultrasonic booster is a one half-wavelength long resonant section made of aluminum or titanium. It is mounted between the Ultrasonic transducer and the Ultrasonic horn, and modifies the amplitude of vibration applied to the Ultrasonic horn.

The success of an ultrasonic plastics assembly application is dependent on the required force, time, and velocity factor to obtain the correct energy level. The ultrasonic velocity factor is obtained by using the correct ultrasonic horn and ultrasonic booster combination to provide the optimum amplitude for the type of plastic, size of part, and type of assembly to be per-formed. Since it may be technically impractical to design the correct amplitude into the ultrasonic horn because of its shape, ultrasonic boosters are used to either increase or decrease the amplitude at the ultrasonic horn face to transmit the required energy to the joint interface.

To enlarge the amplitude , the ultrasonic booster will have different diameters and mass on either side of its center or nodal point.

An amplitude increasing booster has a smaller mass at the end attached to the ultrasonic horn, while an amplitude decreasing ultrasonic booster has a greater mass at the end attached to the ultrasonic horn.

Choosing the Correct ultrasonic Booster: When selecting a ultrasonic booster to be used for an application, it is recommended to use the lowest gain ratio possible that will provide acceptable application results for correct amplitudes values. This will help to operate the ultrasonic horns at lower fatigue levels, which increases tooling reliability.

Ultrasonic horns are designed to be operated with a maximum ultrasonic booster limitation so they will not exceed unreliable fatigue stress levels. The maximum ultrasonic booster limits for special ultrasonic horns are etched directly on the ultrasonic horn along with the horn identification numbers.