Horn Resurfacing Frequency

This chart is based on real life industrual processing examples. Horns are separated by frequency by their vertical position.

This chart shows how many weeks horns can last before they need to be refurbished.

The technical experts at Aurizon Ultrasonics have invested many years and millions of dollars in rotary ultrasonic research and development—including advanced acoustic tool (sonotrode) modeling, fabrication and analysis. In our rotary bonders, the sonotrode (horn) delivers the ultrasonic motion radially around the disc circumference to the material being processed.

Examples of several of Aurizon's horns.

Aurizon has a tremendous variety of horns; a select few shown above.

Some of that research and development has paid off in the understanding of what can be done from a design standpoint to extend the life of the horn. We have designed the pattern placement on many of our anvils so that they evenly distribute wear across the width of the horn. We also offer bonders with independent drives that optimize the speed relationship between the horn and anvil, which can maximize the duty cycle of the horn.

How long will a horn last?
Horn life is based on the application and the materials being bonded, which can vary greatly. It is important to know what to expect in regards to the service life of the horn in a bonder so that you can determine its return on investment and create a maintenance schedule that minimizes production delay.

How will I know when the horn needs resurfacing?
Substantial wear does not always affect the performance of the horn. A horn that looks abused can still function, so rather than err on the side of resurfacing too soon, you should make sure that it actually needs to be done before going forward. Our experienced team can help you define your evaluation protocol so that you can determine when a horn needs to be resurfaced. In addition, we will work with you to develop a maintenance plan to take care of this valuable asset.

What factors influence horn wear?
The three main factors that impact horn life are metallurgy, material type and the environment in which the horn is operating.

  • Metallurgy—Aurizon has its titanium source material manufactured to a specific proprietary recipe. Over the years, we have developed a manufacturing process that minimizes variability in our horns. Likewise, depending on your application, we may suggest a steel horn, which has a very long lifespan in certain situations.
  • Material type–The materials being processed unquestionably affect the life of the horn. Not surprisingly, heavy and/or bulky materials positively influence horn life by creating a buffer between the horn and anvil that minimizes wear; resulting in longer horn life. Meanwhile, thinner material does not allow the same protection and may have the opposite effect on the life of the horn.
  • Operating environment—The environment in which the horn is operating can range from benign to very aggressive based on application needs, directly influencing wear life of the horn.

What is Aurizon’s process for resurfacing a horn?
Most horns can be resurfaced several times. Aurizon can provide this service for you or, if you would prefer, our technical specialists can train your people to develop the in-house capability to refurbish your horn.

Contact us here or send an email to info@aurizonultrasonics.com.

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