Ultrasonic converters operate under continuous high-frequency mechanical vibration and can eventually require inspection, servicing or replacement. A converter that is damaged, overheated or operating outside its intended characteristics may affect the performance of the entire ultrasonic stack.
Possible warning signs can include inconsistent welding, unusual noise, excessive heating, reduced ultrasonic output, abnormal generator loading or changes in welding cycle performance. However, these symptoms can also originate from other parts of the system, so proper diagnosis is important before replacing components.
This guide explains common warning signs and the checks that can help determine whether an ultrasonic converter should be inspected or replaced.