The objective of this work was to study the differences in the ultrasonic welding of polypropylene compounds involving different fillers. The fillers studied were talc, calcium carbonate, mica, and glass fibers. The welding results of interest were weld strength and weld flash. Various welder parameters were varied to find the effect the process had on specimens molded from each filled compound. These welder parameters were weld time, weld force, trigger force, and amplitude. The results indicate that weld time has the greatest effect on the weld strength of each of the filled compounds. Unfilled polypropylene had the highest weld strength at welding conditions involving high welder parameter values. For each given filler, weld flash was highest at the highest loadings of filler.

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