Ultrasonic Horn Repair / Refurbish / Rework

We were contacted by a prospective customer who was having issues with their 20 kHz ultrasonic welding application (ultrasonically welding clamshells for pliers).  Their welder had begun overloading / faulting out and would no longer complete a weld cycle.  They asked if we worked on ultrasonic tooling that had been built by someone else and our answer was "absolutely".

20 kHz ultrasonic welding horn
as received from our customer

They sent their tooling to Industrial Ultrasonics, Inc for evaluation and it was determined that the aluminum back driver had cracked and needed to be replaced.  We informed our customer that the three titanium front drivers were still functional, but the face details were heavily worn and/or damaged.  Furthermore, the steel anvils on their fixture were also heavily worn and/or damaged.

Our quote for this project included: Build a redesigned 20 kHz aluminum back driver, reface and retune the three existing 20 kHz titanium front drivers, and reface the three steel anvils on the fixture.

We received the order for this project. Once the various components were ready, the three refurbished titanium front drivers were attached to the new aluminum back driver, the steel anvils were mounted back onto our customer's original base plate, and our customer was back in production.

New aluminum back driver w/
three refurbished titanium front drivers.

Industrial Ultrasonics, Inc was able to save our new customer $1,576.00 by utilizing their existing titanium front drivers and fixture, and only replacing the aluminum back driver.  Since this initial order, we have performed similar services on multiple sets of ultrasonic tooling for this customer. 

Tooling ready to ship back to customer