E-MOBILITY
Detailed welding tests in the ultrasonics laboratory can be used to develop a welding process that is gentle on the material and allows a minimum scrap rate
reducing reliance on such chemicals becomes imperative for maintaining a favourable sustainability balance and managing expenses. Ultrasonic welding eliminates the
need for additional joining agents to achieve safe and permanent connections between applications. By using ultrasonic vibrations, the reliance on adhesives and the associated energy requirements are avoided. Machines and production equipment that utilise adhesives require regular cleaning, resulting in downtime that decreases production efficiency. Ultrasonic welding not only offers a positive impact on the environmental balance sheet, but also a more streamlined and efficient production process.
SWITCHING TO SUSTAINABLE MATERIALS The use of plastics in EVs is on the rise. Wherever feasible, there is a push to replace metal applications with plastic alternatives. This shift is primarily driven by the multiple advantages that weight reduction through plastics offers: improved energy efficiency, increased battery life, enhanced handling
and manoeuvrability, and reduced manufacturing costs. By choosing the right plastic,
companies can make an important contribution to sustainable production. Recycled plastics made of polypropylene (PP), polyethylene terephthalate (PET), polyethylene (PE), ABS, PVC, and polystyrene, are particularly suitable. However, the utilisation of recycled plastics presents new challenges for joining processes. Each recycling process affects the quality of the material and subsequently, its ability to weld. Initial welding tests conducted with 100% pure recycled PA 6.6 have demonstrated comparable results to conventional plastics in terms of
appearance, density and tensile strength. This indicates that recycled plastics can be a viable alternative for EV components.
COMBINING SUSTAINABILITY WITH EFFICIENCY To meet the increasingly stringent goals in EV production, companies must focus on improving efficiency and sustainability simultaneously. Ultrasonic welding offers a safe and efficient process that can reduce energy consumption and scrap rates. It also enables the secure joining of more sustainable materials, including recycled plastics. These factors play a crucial role in reducing emissions and preserving critical resources. By embracing ultrasonic welding technology, companies can make strides toward achieving their sustainability goals while enhancing cost-effectiveness in the production of EVs.
The sectional view shows that with pure recycled material, a strong connection can be achieved that is just as cohesive as with conventional PA 6.6 plastic
Markus Haas is Global Head of Sales METALS at Herrmann Ultraschall.
www.herrmannultraschall.com
www.engineerlive.com 29
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