Troubleshooting Threaded Insert Installation in Plastics Insufficient pull-out or torque strength:   • Decrease pressure. • Increase weld time. • Increase amplitude (change booster). • Decrease down speed. • Increase insert interference. • Insert is too small or hole is too large. • Increase hole depth. • Decrease screw length. Horn heats up:   • Decrease amplitude (change booster). • Air cool the horn. • If possible, contact plastic rather than insert. • Check coupling between horn, booster and converter. Damage to insert:   • Decrease weld time. • Decrease amplitude (change booster). • Increase pressure. • Increase down speed. Inserting time is excessive:   • Decrease weld time. • Decrease hold time. • Decrease amplitude (change booster). • Increase pressure. • Increase down speed. • Insert is too large or hole is too small. • Improper fixturing. • Power required exceeds capability of power supply. Application is noisy:   • Use sound enclosure or hearing protectors. • Start the ultrasonics just prior to the horn contacting the insert. • Decrease amplitude (change booster). • Increase pressure. • Increase down speed. • If possible, contact plastic rather than insert. Horn wears prematurely:   • Use hardened steel or carbide faced horn. • Decrease amplitude (change booster). • Insert is too large or hole is too small. • Plastic is too abrasive. Plastic cracks:   • Ensure that ultrasonics is turned on. • Decrease pressure. • Walls surrounding hole are too thin. • Increase weld time. • Decrease amplitude (change booster). • Decrease down speed. • Enlarge hole diameter. Plastic fills the threaded bore of the insert:   • Increase hole depth. • Insert is too large or hole is too small. • Insert is too long. Plastic flows over the top of the insert:   • Adjust positive stop to limit depth of insertion. • Decrease weld time. • Insert is too large or hole is too small. Partial insertion:   • Increase pressure. • Decrease down speed. • Decrease amplitude (change booster). • Increase weld time. • Increase hole depth. • Adjust positive stop. • Check fixturing. • Horn is at the end of its stroke. Insert does not remain inserted:   • Increase hold time. System overloads:   • Decrease pressure. • Decrease down speed. • Decrease amplitude (change booster). • Tune power supply. • Check for loose studs. • Check coupling between horn and booster. • Power required exceeds capability of power supply. Insert Selection | Manufacturing | Reference | About Tri-Star | News | Contact Tri-Star | Site Map Threaded Inserts :: Tapered Inserts | Chevron Inserts | Symmetrical Inserts | Press-in Inserts | Expansion Inserts | Threaded Studs | Mold-in Blind Inserts | Knurled Spacers | Compression Limiters | Custom Parts Tri-Star Industries, Inc. 101 Massirio Dr., Berlin, CT 06037 :: Tel 860-828-7570 :: Fax 860-828-7475 :: sales@tristar-inserts.com