Ultrasonic converters and ultrasonic transducers are one in the same. There is one ultrasonic OEM, Dukane Corporation, that uses the term transducer. All of the other ultrasonic OEM manufacturers, such as Branson, Sonics and Materials, Rinco, Telesonics, and Herrmann, refer to these items as converters. The team at BEK Ultrasonics is here to assist you with any questions you may have about the products we sell and repair.
Converters or transducers all do the same thing – they convert electrical energy to mechanical movement. When in use, an electrical charge is introduced across the surface of the ceramics at the desired frequency, which in turn gives us a movement or vibration at the working end of the converter. The converter is threaded onto a booster, which increases, decreases, or transfers the amount of movement from the face of the converter to the horn. If you live in Europe, this is known as the sonotrode.
The horn contacts the part, vibrates for a few milliseconds under a preset pressure, then continues to apply pressure for a few more milliseconds after vibrations have stopped. This is referred to as weld time and hold time. Both can vary quite a bit depending upon the configuration of the part being welded and the plastic composition of that part.
Additional power is required from the generator when a larger horn and booster is used. In this case, stress is placed on the converter. Furthermore, the total duration of the weld and the pressure applied increases the need for power.