Troubleshooting

PROBLEM PROBABLE CAUSES SOLUTIONS
Inconsistent
weld results
part-to-part
(continued)
Drop in air line pressure.
Filler content too high.
Non-uniform distribution of filler.
Incorrect joint design.
Poor part fit.
Incompatible materials or resin
grades or lots.
Moisture in molded part.
(Usually nylon parts.)
Raise compressor output pressure.
Add surge tank with a check valve.
Check air supply line capacity vs. number of welders supplied.
Reduce percentage of filler.
Check molding conditions.
Change type of filler, i.e., short- to long-glass fibers.
Check molding conditions.
Check mold design.
Redesign joint, check with Branson applications engineering.
Improve part dimensions.
Improve part tolerances.
Check molding conditions and improve.
Check Branson Technical Information Sheet PW-1.
Check with resin supplier specifications.
Check with Branson Applications Lab.
Receive parts dry-as-molded, bagged and sealed.
Dry parts, then weld.
Marking Lack of parallelism.
Shear interference too great.
Energy director too large.
No joint design (butt surfaces).
Improper fit of part to fixture.
Weld cycle is too long.
Readjust for parallelism between horn, part, and fixture.
Check horn/part fit.
Check part/fixture fit.
Level fixture where necessary.
Reduce interference.
Reduce energy director size.
Check for proper support.
Redesign fixture.
Check for cavity-to-cavity variations.
Check part dimensions.
Check for cavity-to-cavity variations.
Obtain a new horn.
Reduce weld time by adjusting amplitude and/or pressure.
Adjust Dynamic Triggering pressure.