Hybrid Vibration Welding

Vibration welding with an IR preheat for cleaner parts

Hybrid vibration welding uses an infrared preheat to soften the weld ribs before applying linear vibration to join the parts together. This innovative process improves weld aesthetics and reduces particulate flash.

How does hybrid vibration welding work?

Two components are vibrated in shear against each other generating heat from friction. Vibration stops and pressure is maintained while the components bond to one another.

Hybrid vibration welding adds an infrared (IR) preheat to the beginning of the cycle to soften the rib and reduce the amount of particulate flash generated from the vibration cycle.

Preheat portion of the process of hybrid vibration welding

Preheat

Two components are brought near an infrared heating element to preheat the weld joint.

Clamp portion of the process of hybrid vibration welding

Clamp

The infrared heating element is retracted, and the components are clamped together.

Vibrate portion of the process of hybrid vibration welding

Vibrate

The upper component is vibrated against the lower component, generating friction and heat.

Cool portion of the process of hybrid vibration welding

Cool

Vibration stops and clamp pressure is maintained until the weld cools.

An impressive machine

Extol has partnered with CEMAS to bring you the best hybrid vibration welders. These impressive machines are highly customizable to meet any customer’s needs.

Hybrid Vibration welding full machine

Hybrid Vibration Welder Benefits

Highly customizable

Even with many included standard features, we offer a full range of over 60 options to meet your specific needs.

Clean weld joint

Hybrid vibration welding softens the joint with IR preheat before the vibration process to minimize particulate flash.

No compromise for quality

All components are from world leading suppliers. Safety is our ultimate goal, as well as a prompt availability of spares worldwide.

Easy maintenance

The latest-generation electronic components and strategic placement of the hydraulic unit have resulted in a remarkably smaller control panel. It has also made tooling maintenance and setup operations easier.

Innovative and user-friendly UI

The graphical interface is the most intuitive on the market. Language selection, parameter adjustment, and user-configured I/O is as easy as the touch of a button.

Ergonomic loading

To minimize strain on the backbone, the loading/unloading area is as close to the operator as possible. Our vibration welders have a shorter loading distance than any other machines in their class.

Hybrid welding and 4 reasons why you might need it

  • To optimize weld aesthetics and reduce particulate flash
  • To avoid stringing
  • To reduce stress in the weld joint and improve strength
  • To weld geometries that may not be feasible using vibration welding alone

Hybrid Vibration Welder Models

There are several different hybrid vibration welder models available.

901 Model of Hybrid Vibration Welding

901

Small and Efficient

Ideal for welding small to medium size taillights, intake manifolds, and glove boxes.

911 Model of Hybrid Vibration Welding

911

Compact and Flexible

Ideal for welding large rear lamps, intake manifolds, spoilers, etc.

912 Model of the Hybrid Vibration Welder

912

Born Hybrid

The most advanced in the range, it combines vibration and infrared technology within a compact body.

918 Model of the Hybrid Vibration Welder

918

Big Inside

Born to weld the same products welded by 911, but require a stronger welding force and an increased workspace.

Features

Red circle with blue ovals around it

Real-time tuning

Real-time tuning adjusts the vibration frequency every 5 ms to ensure a perfect match between the resonating tool mass and the characteristics of the application.

Four teal arrows in different directions

Wide rear opening

Wide rear opening in the back of the machine for easier tool changes.

Red octagon with a white exclamation point in the middle

Quick vibration stop

Vibration can be stopped in less than 50 ms for a more homogeneous and strong joint.

Learn how to design for hybrid vibration welding.

A properly designed weld joint is important to achieving a strong weld. Follow our easy-to-use guidelines to optimize your part design for hybrid vibration welding.

Learn more about hybrid vibration welding on our blog.

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