Troubleshooting

product nameTL-24
PROBLEM PROBABLE CAUSES SOLUTIONS
Marking
(continued)
Horn heats up.
Localized high spots in part.
Raised lettering.
Aluminum oxide (from horn).
Overwelding: control mode
(time, energy, collapse or
absolute distance, peak power,
force) too high.
Check for loose tip.
Reduce weld time. Cool horn with ambient or refrigerated air.
Check coupling between horn and booster.
Visually check for cracked horn.
If horn is titanium, change to chrome-plated aluminum.
Check part dimensions.
Check fit of horn to part in fixture.
Use polyethylene film between horn and part.
Relieve horn.
Use recessed lettering where possible.
Chrome-plate or clear anodized horn and/or fixture.
Use polyethylene film between horn and part.
Readjust control parameters.
Flash (see also
non- uniform
welding)
Weld time too long.
Non-uniform joint dimensions.
Energy director too large.
Shear interference too great.
No joint design (butt surfaces).
Reduce weld time.
Redimension joint.
Check molding conditions.
Reduce size of energy director.
Reduce weld time.
Reduce pressure.
Use textured surface.
Reduce amount of interference.
Redesign joint to direct flash as required by application.
Misalignment
of welded
assembly
Lack of proper alignment feature
between mating parts.
Improper support in fixture.
Wall flexure.
Add alignment feature to the mating part halves (i.e., pins and
sockets).
Redesign fixture for proper support.
Shim fixture where necessary.
If large sections of urethane are deflecting, add rigid backup.
Add ribs or gussets to part.
Increase wall thickness.
If large sections of urethane are deflecting, add rigid backup.