Johnson’s wide experience supports successful application development for your welding needs. With extensive expertise, Johnson can develop your application and tooling essential for the success of ultrasonic welding, a crucial aspect of the process.

Horns can be made in Tool Steel, Special Aluminium Alloy, and Aluminium Alloy. Fixtures are customized to meet specific needs. Steel horns are heat-treated, while Aluminium horns are hard anodized to ensure durability over extended periods.

In welding, “horns and fixtures” refer to tools and equipment designed to facilitate precise and effective welding operations. These components are crucial in industries requiring consistent and repeatable welds, such as automotive, aerospace, and manufacturing.

In Ultrasonic or Resistance Welding, horns (also known as sonotrodes in ultrasonic welding) play a critical role in transmitting energy to the materials being welded. They are:

• Made from hardened steel, titanium, or aluminum to withstand high forces and wear.
• Custom-shaped based on the welding application, material type, and desired weld area.

Fixtures are devices used to securely hold and position parts during the welding process. They ensure accuracy, consistency, and operator safety.

• Manual Fixtures: Require operator setup and adjustment. Used for simple or low-volume welding operations.
• Pneumatic or Hydraulic Fixtures: Use compressed air or hydraulic pressure to secure parts. Provide faster setup times and are suitable for repetitive tasks.
• Magnetic Fixtures: Use strong magnets to hold ferromagnetic materials in place. Ideal for quick setups and temporary positioning.
• Customized Welding Jigs: Designed specifically for unique parts or welds. Provide maximum accuracy and repeatability.

• Improved weld quality and precision.
• Faster production speeds due to reduced setup times.
• Reduced operator fatigue by automating part alignment and clamping.
• Minimized deformation or movement of parts during welding.

• Ultrasonic Welding: For joining plastics, non-ferrous metals, or delicate materials.
• Resistance Welding: In automotive assembly for spot welding.
• Arc Welding: To hold complex assemblies or ensure precise alignment.

• Regular Inspection: Ensure horns and fixtures are free from damage or wear that could impact performance.
• Proper Cleaning: Remove debris and contaminants to maintain accuracy.
• Calibrations: Periodically check and recalibrate fixtures to ensure consistency.
• Operator Training: Workers should be familiar with the specific tools and their safe use.