FAQs – Ultrasonic Metal Welding

What materials can be welded by ultrasonic metal welders?

Ultrasonic metal welders can easily weld aluminum, brass, copper, most precious metals, and nickel alloys. Additionally, ultrasonic welding offers the advantage of being able to join many dissimilar metal combinations.

What are the advantages of ultrasonic metal welding over crimping?

• It does not require any additional materials.
• It can join wire-to-wire or wire-to-terminals without fillers or crimping tools.
• Ultrasonic welds provide a more secure and durable bond over time compared with crimped wires.

What is the maximum wire bundle the ultrasonic wire splicer can handle?

We generally recommend a maximum bundle size of 200 sq. mm for bare stranded copper for our powerful WeldMAX™ system.. For our 3500 watt single head wire splicer, we have successfully welded bundles up to 40 sq. mm with a single pulse. For our dual head wire splicer, we can weld up to 100 sq. mm.

How long does the tip last, on average?

The heat-treated tool steel tip can typically last for up to 100,000 welds before it requires replacement.

What are the differences between wedge reed and lateral drive welding methods?

Sonobond uses the wedge reed system, in which the transducer/horn drives a reed. This red contains a tapered cavity where the tip is inserted. Advantages include:

• The force of the cylinder is directly above the weld spot, ensuring efficient energy transfer.
• The tip is easily replaceable, reducing downtime.

By contrast, the lateral drive method uses a transducer/horn with a small extension to contact the welded piece. Drawbacks:

• When the tip extension wears out, the entire horn must be replaced, sometimes requiring system recalibration.
• The force of the cylinder is offset, rather than being directly above the weld spot.