The booster body is rigidly supported by a collar that is electron-beam welded to the booster's node. Because the rigid booster is constructed only of metal (no compliant elastomers), it has excellent axial and lateral stiffness. For additional stiffness a second collar can be incorporated into a full-wave design.
The collar is tuned to isolate the motion of the booster body from the support
structure. This is shown is the following image of a displaced booster, where the coolest
colors indicate the lowest amplitudes.
Notes: For all images, the output surface (face) is at the top and the input surface is at the bottom. All results are from finite element analysis.
The nominal resonant frequency of the booster is the same as the nominal resonant frequency of the ultrasonic stack in which it is used.
The maximum booster gain is usually limited to about 3:1 (depending on the output amplitude of the transducer) in order to to avoid fretting problems at front (output) interface. In some cases, the booster is integrated directly into the horn (a one-piece design) or electron-beam welded to the horn to avoid such problems.
Boosters with gains up to about 1.5:1 can be made of aluminum. Higher gain boosters are generally made of titanium in order to reduce fatigue failures.
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