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Symptom	Cause	Solution
Over-welding	Excessive welding energy is input.	Reduce welding time. Reduce pressure. Reduce amplitude (replace amplifier). Adjust power to a lower grade.
Infirm welding	Insufficient welding energy is input.	Increase welding time. Increase holding time. Increase amplitude (replace amplifier). Increase pressure.Adjust power to a higher grade. Replace with a high-power welder.
Infirm welding	In-built parts too high	Reduce the height of the parts.
Uneven welding	Bent workpiece	Check if the weldment is deformed.Check welding conditions.Adjust jogging speed.
	Uneven welding point	Uneven height of ultrasonic lines, needs redesign.
	Unfitting contact interfaces of welding head,base and weldment.	Pad the base.Check the dimensional sizes of weldment.Pad tinfoil under weldment.
	Lateral walls bent	Apply reinforcement to weldment.
	Poorly aligned weldment.	Check the welding to see if the weldment is tilted. Check if the weldment assembly is aligned.Check if the welding head, weldment and amplifier are parallel.
	Infirm weldment jointing	Check the size and tolerance of the weldment. Check if the weldment is defective. Check the position of the faying face center. Clean the faying face of workpiece.
Inconsistent welding effect	Multiple pieces for one mold,not interchangeable	Make new molds. Categorize weldments.
	Release agent polluted	Clean weldment faying face.
	Instable voltage or pressure	Improve voltage or pressure.
	Inconsistent material quality	Contact material suppliers.
	Moist nylon weldment or wet molds	Bake molds and weldment.
Defects on weldment surface	Overheated welding head	Check if the screw of the welding head is loose. Check if the welding head is broken. Cool the welding head.Shorten welding time. Replace with aluminum alloy if the welding head is titanium. Reduce amplification times if the welding head is steel.
	Polluted by alumina	Use polyethylene film. Treat welding head with chromium.
	External damage of the welding head	Make new welding heads
Internal damage of weldment	Workpiece absorbs too much energy	Reduce amplitude. Reduce pressure. Shorten welding time.
Internal damage of weldment	Improper assembling of parts	Redesign assembliesIsolate internal parts from the enclosure
Weldment broken when welding	Excessive stress in weldment	Adjust injection parameters.Modify weldment design
Rough edges on faying face	Excessive area of ultrasonic lines	Modify welding lines
Rough edges on faying face	Weldment too tight	Loosen weldment bonding.

　>> Embedding:：

Symptom	Cause	Solution
Workpiece broken after embedding	Ultrasonic wave failed to be triggered on time	Reduce time delay. Reduce pressure. Decelerate jogging speed.
	Hole diameter too small or hole wall too thin	Increase hole diameter or hole wall thickness
	Fillers exceeding 30%	Reduce filler content.
Embedded parts easy to pull out	Improper hole diameter	Improve hole diameter
	Continue to impact on embedded parts with welding head after complete embedding	Shorten welding time
	Screw so long as to reject the welding head	Modify screw size.
	Plastics fail to cure after pressure is relieved	Increase holding time.
Embedding time too long	Insufficient power for ultrasonic wave	Replace with a high-power type.
Embedding time too long	Lowering speed too slow	Regulate one-way valve to accelerate lowering speed.
Recess occurs at welding head	Insufficient hardness for welding head	Use heat-treated titanium alloy or steel for welding head.
Recess occurs at welding head	Excessive high ultrasonic amplitude	Reduce amplitude
Excessive noise	In ultrasonic embedding metal collides with metal and high noise is unavoidable.	Wear ear muffs, reduce amplitude and increase pressure.
Plastics spilling over embedded surface	Embedded too deep	Reduce embedding depth.
	Welding time too long	Reduce welding time.
	Hole diameter too small	Enlarge hole diameter.

　>> Riveting：

Symptom	Cause	Solution
Uneven riveting	Riveting cavity too large	Reduce riveting cavity size.
Uneven riveting	Rivet too small	Increase rivet size.
Incomplete riveting	Insufficient riveting time	Increase riveting time.
Rivet root broken in riveting	Stress at rivet root too centralized	Change the angle of rivet root and transit in arc.
Rivet root broken in riveting	Welding head not perpendicular with rivet	Calibrate again.
Weldment becomes loose after welding	Rivet fails to cure after pressure is relieved	Extend holding pressure.
Weldment becomes loose after welding	Insufficient travel of welding head	Adjust travel of welding head.
Spilling around riveting poin	Riveting cavity too smallRivet too small	Increase riveting cavity size.Reduce rivet size.
	Rivet too small	Reduce rivet size.
	Poorly aligned centers for rivet, welding head and rivet cavity	Calibrate again.
Defects on opposite side of weldment	Improper base support, excessive pressure	Change supporting method, reduce pressure

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