Automotive & Motorsports

🔊 Ultrasonic Welding Components

Cylindrical/prismatic stepped profile, threaded mounting stud, precision contact face, tuned half-wave length

10 Components 1 Materials 3 Processes 8 Standards

What is Ultrasonic Welding Components?

🔊 Ultrasonic Welding Components represents a complete system of precision titanium components engineered for Automotive & Motorsports applications. Cylindrical/prismatic stepped profile, threaded mounting stud, precision contact face, tuned half-wave length The system integrates 10 distinct component types manufactured through 3 specialized processes.

Key manufacturing processes for this system include CNC turn-mill multi-axis for ultrasonic tooling geometry, Shot peening Almen at 200W fiber laser, Black oxide/DLC coating at 200W fiber laser, CMM SPC dimensional check at 200W fiber laser, Shot peening Almen with 0.5mm corner radius, each selected and qualified to meet component-specific requirements.

Engineering & Design Principles

Material: Grade 5 (Ti-6Al-4V) is the industry standard for ultrasonic welding components — unmatched acoustic velocity (5090 m/s) and infinite fatigue life under 20-40kHz resonance. Material must be triaxially

Form: Forged blocks from triaxially rolled bar stock for horns and boosters. CNC turning + nodal line optimization profiling. Every horn must be frequency-tuned via digital frequency analyzer to target +-50

Standards & Material Specifications

Standards: ASTM B348 Grade 5, solution-treated (STA), frequency-tuned to customer specification, Ra<=0.4um contact face

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Engineering Solution Blueprint

Ultrasonic Welding Components

Automotive · Consumer · Medical Device

1 Part Feature Analysis

Cylindrical/prismatic stepped profile, threaded mounting stud, precision contact face, tuned half-wave length

  • ⚠️ Acoustic fatigue
  • ⚠️ Contact face wear
  • ⚠️ Thread stripping at high amplitude
  • ⚠️ Frequency drift
  • ⚠️ Heat generation

2 Material Selection Rationale

Grade 5 Ti-6Al-4V — General alpha-beta alloy, high strength

Grade 5 (Ti-6Al-4V) is the industry standard for ultrasonic welding components — unmatched acoustic velocity (5090 m/s) and infinite fatigue life under 20-40kHz resonance. Material must be triaxially forged (3-axis cross-rolling) to ensure isotropic grain structure — standard plate stock has directional grain alignment that causes acoustic wave refraction and cracking. ELI Grade 23 for medical sonotrodes requiring bio-inertness.

3 Form Selection Rationale

Round Bar / Rod — for turning, fasteners

Forged blocks from triaxially rolled bar stock for horns and boosters. CNC turning + nodal line optimization profiling. Every horn must be frequency-tuned via digital frequency analyzer to target +-50Hz at specified clamping torque.

4 Manufacturing Process & Services

Core Processes:

Triaxial forging of billet for isotropic grain structureCNC turning + nodal profile milling of sonotrodeDigital frequency analysis (DFA) tuning to +-50Hz targetDynamic balancing for rotary hornsCryogenic polishing for medical sonotrodes

Toll Processing Services:

CMM inspectionImpedance / frequency analysisDLC coating (wear resistance)Laser marking

Process Pitfalls:

  • ⚠️ Half-wave resonance tuning must be within +-50Hz of target frequency
  • ⚠️ Contact face flatness must be <0.005mm for consistent weld quality

5 Procurement Specifications

ASTM B348 Grade 5, solution-treated (STA), frequency-tuned to customer specification, Ra<=0.4um contact face

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Manufacturing Process Flow

1
CNC turning + nodal profile milling of sonotrode

CNC turning of titanium on multi-axis lathes produces cylindrical components with precision diameters and surface finishes. Live tooling enables milli

2
Digital frequency analysis (DFA) tuning to +-50Hz target

Professional manufacturing process for titanium components. Digital frequency analysis (DFA) tuning to +-50Hz target is performed by certified technic

3
Triaxial forging of billet for isotropic grain structure

Closed-die forging of titanium uses shaped dies to compress a heated billet into a net-shape or near-net-shape component. The process aligns grain flo

Components in This System

Component Material
Titanium Acoustic Waveguide Extension Grade 5 Ti-6Al-4V (Triaxially Forged)
Titanium Ultrasonic Booster 35kHz Grade 5 Ti-6Al-4V (Triaxially Forged)
Titanium Ultrasonic Connecting Stud Grade 5 Ti-6Al-4V (Triaxially Forged)
Titanium Ultrasonic Food Cutting Blade Grade 5 Ti-6Al-4V (Triaxially Forged)
Titanium Ultrasonic Horn 20kHz Grade 5 Ti-6Al-4V (Triaxially Forged)
Titanium Ultrasonic Knurled Insert Grade 5 Ti-6Al-4V (Triaxially Forged)

Frequently Asked Questions

What titanium grades are used in Ultrasonic Welding Components systems?
Ultrasonic Welding Components components are manufactured from Grade 5 Ti-6Al-4V (Triaxially Forged). The specific grade is selected based on mechanical property requirements, corrosion resistance needs, and Automotive & Motorsports industry regulations.
What manufacturing processes are used for Ultrasonic Welding Components?
The Ultrasonic Welding Components system components are produced using CNC turn-mill multi-axis for ultrasonic tooling geometry, Shot peening Almen at 200W fiber laser, Black oxide/DLC coating at 200W fiber laser, CMM SPC dimensional check at 200W fiber laser, Shot peening Almen with 0.5mm corner radius, Black oxide/DLC coating with 0.5mm corner radius. Each process is selected and qualified to meet the specific dimensional, metallurgical, and surface requirements of each component within the system.
What quality standards apply to Ultrasonic Welding Components components?
Ultrasonic Welding Components components are manufactured to ISO 26262 (acoustic waveguide applied), ISO 26262 (35khz highgain applied), ISO 26262 (m12x125 horntobooster applied), ISO 26262 (ultrasonic food applied), ISO 26262 (20khz cylindrical applied) and other applicable specifications. Full material traceability, dimensional inspection reports, and certificates of conformance are provided with each shipment.
What industries use Ultrasonic Welding Components?
Ultrasonic Welding Components systems are deployed in Automotive & Motorsports applications. Each industry has specific regulatory and performance requirements that drive material selection and process qualification.
Can you provide DFM feedback for Ultrasonic Welding Components designs?
Yes. Our engineering team provides free Design for Manufacturability (DFM) analysis for Ultrasonic Welding Components projects. Upload your CAD file (STEP, DXF, or DWG format) and our team will review your design within 24 hours.

Engineering Trends

  • ▸ Process: Triaxial forging of billet for isotropic grain structure
  • ▸ Process: CNC turning + nodal profile milling of sonotrode
  • ▸ Process: Digital frequency analysis (DFA) tuning to +-50Hz target

Related Manufacturing Capabilities

These specialized processes support Ultrasonic Welding Components component manufacturing.

CNC turning + nodal profile milling of sonotrode Digital frequency analysis (DFA) tuning to +-50Hz target Triaxial forging of billet for isotropic grain structure
About Boze Titanium Manufacturing Center

One Metal. One Focus. Infinite Precision.

Founded in 2011 in Baoji's Titanium Valley, BOZE Metal is dedicated exclusively to titanium — from raw material to precision engineering. AS9100D, ISO 13485 & ISO 9001 certified with 500+ clients across Aerospace, Medical & Motorsport industries, we deliver end-to-end precision titanium CNC machining with full material traceability from source to component.

Boze CNC Ti is the dedicated titanium manufacturing center of Baoji Boze Metal Products Co., Ltd.

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