Troubleshooting

PROBLEM PROBABLE CAUSES SOLUTIONS
Misalignment
of welded
assembly
(continued)
Joint design improper dimension.
Part tolerance/poor molding.
Overwelding.
Redimension parts.
Tighten part tolerances.
Check molding conditions.
Reduce weld time/energy/pressure.
Internal
components
damaged during
welding
Too much energy into the part.
Long weld time.
Components improperly mounted, i.e.,
mounted too close to joint area, etc.
Location of components.
Reduce amplitude by changing to a lower gain booster, or utilize
Amplitude Profiling.
Reduce pressure and/or down speed.
Reduce weld time/energy.
Adjust Dynamic Trigger pressure.
Investigate the use of alternate frequencies.
Reduce weld time by adjusting amplitude and/or pressure.
Adjust Dynamic Triggering pressure.
Make sure internals are properly mounted.
Isolate internal components from housing.
Move components away from areas of high energy concentration.
Use nodally-mounted device to dampen energy locally.
Components should be in fixture part.
Melting/fracture
of part sections
outside of joint.
Too much energy into the part.
Sharp internal corners.
Excessive amplitude.
Internal stress.
Knit/flow lines.
Improper molding conditions.
Gate located near joint.
Reduce weld time.
Decrease amplitude.
Decrease pressure.
Adjust Dynamic Triggering pressure.
Radius all sharp corners.
Reduce amplitude by changing to a lower gain booster, or
step amplitude.
Reduce horn amplitude if lowest booster is already in use.
Monitor/improve molding conditions.
Check part design.
Check molding process parameters.
Check molding conditions.
Move gate area away from joint.