The ultrasonic horn is one of the most important working components in a plastic welding system because it directly transfers vibration to the workpiece. Continuous production can eventually cause wear, especially when the horn is exposed to demanding materials, high production volumes or improper operating conditions.
Changes in weld quality, unusual noise, heating, visible cracks, surface damage or changes in horn frequency can indicate that tooling needs inspection. A worn or modified horn can also behave differently from its original design because machining changes may affect its resonant characteristics.
This article explains the signs of ultrasonic horn wear and when manufacturers should consider inspection, tuning, repair or replacement.