Ideally, in ultrasonic welding the area where the horn contacts the part should be as close to the part joint as possible. However, at times, odd-shaped and sized parts prevent a half-wave horn from contacting the part where needed or developing sufficient amplitude to weld the application. In these situations, the answer is to use of a composite/compound horn.
What is a composite horn?
A composite horn is several individual horns (commonly referred to as “horn tips”) attached to a coupling horn to form a single, tuned, full-wavelength unit.
Large coupling horn made from aluminum or titanium, as determined by the size and amplitude requirements of the application.
Horn Tips – the individual “working horns” are made from either titanium or steel.
Benefits of using composite horns:
Reduce internal horn stress by building higher amplitude on the horn tip. The amplitude at the face of a composite horn is substantially higher than what could be delivered by a single, large horn.
Easily welds hard to reach weld areas. Composite horns have been used to solve the amplitude or wear problems encountered in large, multiple insertions, staking, and stud welding applications.
Eliminates the need for multiple welders. They can provide greater part coverage, which in some cases can eliminate the need for multiple welders.
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