Material Drying
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PA66 weld line fusion
Problem Phenomenon
PA66 two-piece set leaks in sealing test after ultrasonic welding
Cause Analysis
Contaminated welding surfaces or inconsistent moisture content cause poor fusion; unreasonable energy director design disperses energy; during on-site troubleshooting, verify item by item according to this mechanism, avoiding blindly adjusting the machine based only on experience
Solution
Clean and dry welding surfaces; unify material moisture conditioning state; design energy director cross-section according to material thickness; full air-tightness inspection after welding; after adjustment, take continuous samples to verify the effect, confirm stability before resuming mass production
Key Takeaway
Welding sealing is guaranteed by interface state and energy director design; after confirming effectiveness, fix the parameters and practices into the work instructions to prevent recurrence; include this case in the defect archive as a troubleshooting reference for subsequent similar problems
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