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Certificate #10254
1000 Piece / $125 Minimum Order
Quality threaded inserts, made in America
Tri-Star Inserts are RoHS Compliant
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Tri-Star Industries, Inc. Troubleshooting Guide for Inserting
Troubleshooting Threaded Insert Installation in Plastics
Insufficient pull-out or torque strength:
  Decrease pressure.
Increase weld time.
Increase amplitude (change booster).
Decrease down speed.
Increase insert interference.
Insert is too small or hole is too large.
Increase hole depth.
Decrease screw length.
Horn heats up:
  Decrease amplitude (change booster).
Air cool the horn.
If possible, contact plastic rather than insert.
Check coupling between horn, booster and converter.
Damage to insert:
  Decrease weld time.
Decrease amplitude (change booster).
Increase pressure.
Increase down speed.
Inserting time is excessive:
  Decrease weld time.
Decrease hold time.
Decrease amplitude (change booster).
Increase pressure.
Increase down speed.
Insert is too large or hole is too small.
Improper fixturing.
Power required exceeds capability of power supply.
Application is noisy:
  Use sound enclosure or hearing protectors.
Start the ultrasonics just prior to the horn contacting the insert.
Decrease amplitude (change booster).
Increase pressure.
Increase down speed.
If possible, contact plastic rather than insert.
Horn wears prematurely:
  Use hardened steel or carbide faced horn.
Decrease amplitude (change booster).
Insert is too large or hole is too small.
Plastic is too abrasive.
Plastic cracks:
  Ensure that ultrasonics is turned on.
Decrease pressure.
Walls surrounding hole are too thin.
Increase weld time.
Decrease amplitude (change booster).
Decrease down speed.
Enlarge hole diameter.
Plastic fills the threaded bore of the insert:
  Increase hole depth.
Insert is too large or hole is too small.
Insert is too long.
Plastic flows over the top of the insert:
  Adjust positive stop to limit depth of insertion.
Decrease weld time.
Insert is too large or hole is too small.
Partial insertion:
  Increase pressure.
Decrease down speed.
Decrease amplitude (change booster).
Increase weld time.
Increase hole depth.
Adjust positive stop.
Check fixturing.
Horn is at the end of its stroke.
Insert does not remain inserted:
  Increase hold time.
System overloads:
  Decrease pressure.
Decrease down speed.
Decrease amplitude (change booster).
Tune power supply.
Check for loose studs.
Check coupling between horn and booster.
Power required exceeds capability of power supply.
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Tri-Star Industries, Inc.
101 Massirio Dr., Berlin, CT 06037 :: Tel 860-828-7570 :: Fax 860-828-7475 ::
sales@tristar-inserts.com