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Symptom

Cause

Solution

Over-welding

Excessive welding

energy is input.

Reduce welding time.

Reduce pressure.

Reduce amplitude (replace amplifier).

Adjust power to a lower grade.

Infirm welding

Insufficient welding

energy is input.

Increase welding time.

Increase holding time.

Increase amplitude (replace amplifier).

Increase pressure.Adjust power to a higher grade.

Replace with a high-power welder.

In-built parts too high

Reduce the height of the parts.

Uneven

welding

Bent workpiece

Uneven welding point

Pad the base.Check the dimensional sizes of

weldment.Pad tinfoil under weldment.

Lateral walls bent

Apply reinforcement to weldment.

Poorly aligned weldment.

Check the welding to see if the weldment is tilted.

Check if the weldment assembly is aligned.Check if the

welding head, weldment and amplifier are parallel.

Check the size and tolerance of the weldment.

Check if the weldment is defective.

Check the position of the faying face center.

Clean the faying face of workpiece.

Inconsistent

welding

effect

Multiple pieces for

one mold,not

interchangeable

Make new molds.

Categorize weldments.

Release agent polluted

Clean weldment faying face.

Instable voltage or pressure

Improve voltage or pressure.

Inconsistent material quality

Contact material suppliers.

Moist nylon weldment or wet molds

Bake molds and weldment.

Defects on weldment surface

Overheated welding head

Check if the screw of the welding head is loose.

Check if the welding head is broken.

Cool the welding head.Shorten welding time.

Replace with aluminum alloy if the welding head is

titanium.

Reduce amplification times if the welding head is

steel.

Polluted by alumina

Use polyethylene film.

Treat welding head with chromium.

External damage of the

welding head

Make new welding heads

Internal damage of weldment

Workpiece absorbs too much energy

Reduce amplitude.

Reduce pressure.

Shorten welding time.

Improper assembling of parts

Redesign assembliesIsolate internal parts from the

enclosure

Weldment broken when welding

Excessive stress in weldment

Adjust injection parameters.Modify weldment design

Rough edges on faying face

Excessive area of

ultrasonic lines

Modify welding lines

Weldment too tight

Loosen weldment bonding.

Workpiece

broken after

embedding

Ultrasonic wave failed to be triggered on time

Reduce time delay.

Reduce pressure.

Decelerate jogging speed.

Hole diameter too small or hole wall too thin

Increase hole diameter or hole wall thickness

Fillers exceeding 30%

Reduce filler content.

Embedded parts easy to pull out

Improper hole diameter

Improve hole diameter

Continue to impact on embedded parts

with welding head after complete

embedding

Shorten welding time

Screw so long as to reject the welding head

Modify screw size.

Plastics fail to cure after pressure is relieved

Increase holding time.

Embedding time

too long

Insufficient power for ultrasonic wave

Replace with a high-power type.

Lowering speed too slow

Recess occurs

at welding head

Insufficient hardness for welding head

Excessive high ultrasonic amplitude

Reduce amplitude

Excessive noise

In ultrasonic embedding metal

collides with metal and high noise is

unavoidable.

Wear ear muffs, reduce amplitude and

increase pressure.

Plastics spilling over embedded surface

Reduce embedding depth.

Welding time too long

Reduce welding time.

Hole diameter too small

Enlarge hole diameter.

Uneven riveting

Riveting cavity too large

Reduce riveting cavity size.

Rivet too small

Increase rivet size.

Incomplete riveting

Insufficient riveting time

Rivet root broken in

riveting

Stress at rivet root too centralized

Welding head not perpendicular with rivet

Calibrate again.

Weldment becomes loose

after welding

Rivet fails to cure after pressure is

relieved

Extend holding pressure.

Insufficient travel of welding head

Adjust travel of welding head.

Spilling around

riveting poin

Riveting cavity too smallRivet too small

Increase riveting cavity

size.Reduce rivet size.

Rivet too small

Reduce rivet size.

Poorly aligned centers for rivet, welding

head and rivet cavity

Calibrate again.

Defects on opposite

side of weldment

Improper base support, excessive

pressure

Change supporting method,

reduce pressure