Brass Debris Removal Help

[ChrisMilani]

Hi,

We ultrasonically weld Dodge/Pencom threaded inserts into bosses for assemblies, and have had quite an issue with ensuring the finished component is brass debris free. Our normal operation is blowing the part off with compressed air after welded inserts have been welded into part. This has caused brass flake to be in the atmosphere/get introduced to our finished goods packaging.

Anyone had/faced the same issue? Any ideas for a long term solution?

Thanks in advance,

Chris

[Suhas]

Hi,
You will find this issue and is common. Instead of using air to blow it off, can you use a vacuum in that area?
Regards,
Suhas

[pjhall]

We do quite a bit of sonic welding and heat staking. This is a common problem with brass inserts. We have had to switch to stainless inserts on some medical parts to stop flaking, but stainless inserts are more expensive. We also have a small vacuum line at the welder to suck up any flakes as well. Most of the time we blow the parts off with compressed air (with an ionized air nozzle) You could also blow the parts with a static dissipative blower.

[rickbatey]

Adjusting your weld setting lower can also reduce the flaking. At times you may start the horn too early, other times too late. Lowering the max energy or amplitude can help.
Rick.