Troubleshooting Threaded Insert Installation in Plastics
- Decrease pressure
- Increase weld time
- Imcrease amplitude (change booster)
- Decrease down speed
- Increase insert interference
- Insert is too small or hole is too large
- Increase hole depth
- Decrease screw length
- Decrease amplitude (change booster)
- Air cool the horn
- If possible, contact plastic rather than insert
- Check coupling between horn, booster and converter
- Decrease weld time
- Decrease amplitude (change booster)
- Increase pressure
- Increase down speed
- 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
- 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
- Use hardened steel or carbide faced horn
- Decrease amplitude (change booster)
- Insert is too large or hole is too small
- Plastic is too abrasive
- 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
- Increase hole depth
- Insert is too large or hole is too small
- Insert is too long
- Adjust positive stop to limit depth of insertion
- Decrease weld time
- Insert is too large or hole is too small
- 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
- Increase hold time
- 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