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|
Type |
Typical shape | Description |
| Unslotted |
|
Horn width is generally <= 0.4 * wavelength. Moderate gain. Used for plunge and scan welding and for some liquid processing applications (e.g., ultrasonic soldering). |
| Slotted |
|
Horn width is generally >= 0.4 * wavelength. Special design techniques
give optimum face amplitude uniformity. Moderate gain. Used for plunge and scan welding. |
A block horn has a rectangular output face and has slots in two perpendicular directions.
Type |
Typical shape | Description |
| Block |
|
Width and thickness are generally >= 0.4 * wavelength. Unity gain. Used for plastic welding of large, flat, rectangular parts. |
| Composite |
|
High gain tip horns are driven by a common mother horn. Used for spot welding of plastics and for liquid processing. |
| Contoured | ____________ |
A horn that has a complex, often irregular shape machined into its face. Used for plastic welding. |
|
|
This bell horn has an integral booster and is designed for liquid processing. The rigid mount flange provides a hermetic seal against the wall of the pressure vessel. |
| Metal welding |
Tip and nut details |
Metal welding horns have a replaceable annular tip (typically tool steel) that is secured by a nut. The tip has multiple welding lobes. |
|
|
The resonator is driven axially but the disk vibrates radially. Designed
for use with a rigid mount booster. Used for rotary seam welding of plastics. |
| Flexure disk |
|
The flexure disk is driven axially at its center but vibrates in bending
with circular nodes. The amplitude decreases from the center to the edge. Compared to
conventional horns, the disk has a large surface area with low mass. With the proper
contour, the disk can produce a very narrow, intense acoustic beam. Used primarily for airborne ultrasound (drying, defoaming, agglomeration, etc.). |
| Radial sphere |
|
The resonator is driven axially but the sphere vibrates with a uniform
radial motion. The sphere's diameter is approximately twice the axial thin-wire
half-wavelength (about 250 mm at 20 kHz). Used for atomization and cavitation. |
Type |
Typical shape | Description |
| O-ring | ____________ |
The mounting ring is isolated from the booster body by O-rings. |
Rigid mount |
|
Because the rigid mount booster is constructed only of metal (no compliant
elastomers), it has excellent axial and lateral stiffness. Used with heavy loads or where precise positioning is required and for rotating applications (e.g., seam welding; see radial disk). Also used where a hermetic seal at the mounting ring is required (e.g., for mounting through the wall of a pressure vessel); for an example, see the full-wave bell horn. |
|
Cross-
|
|
With a cross-coupled booster, the input and output surfaces are at 90 degrees, so the booster can essentially transmit ultrasound "around a corner". As with conventional boosters, various gains are possible. For the illustrated booster, the output amplitude from the top surface is 2.5 times greater than the input amplitude from the left surface. Note: the cross-coupled booster can also be used directly as a cross-coupled horn. |
Type |
Typical shape | Description |
| Transducer |
3/4 section |
Typical transducer with four piezoelectric ceramics, center-bolt
(Langevin) design. The housing and electrode leads are not shown. For industrial applications, available power can range from 10 watts to 3000 watts, depending on the operating frequency, duty cycle, cooling, ceramic volume, and other factors. |
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