SonoWeld® Ultrasonic Spot Welder

The SonoWeld® ultrasonic spot welder produces strong, reliable solid-state bonds between similar or dissimilar nonferrous metals. It performs spot welding and wire-to-terminal welding without requiring heat, electrical current, fluxes, fillers or consumables. The welder can join multiple metal layers, delicate battery foils, stranded wires, terminals, tabs and other nonferrous metal assemblies. Sonobond’s patented Wedge-Reed System can even weld oxidized or tinned metals in a single pulse without pre-cleaning.

What Is an Ultrasonic Spot Welder?

An ultrasonic spot welder uses high-frequency mechanical vibrations and controlled clamping force to form a solid-state metallurgical bond between metal components. The process disrupts surface oxides and brings the metals into intimate contact without melting the base materials.

Because ultrasonic metal welding generates the bond through mechanical vibration rather than bulk heating, it can join thin, conductive and heat-sensitive materials without damaging nearby components. The SonoWeld system produces each weld in a single pulse, helping manufacturers achieve fast cycle times and repeatable weld quality.

What Metals Can the SonoWeld Ultrasonic Spot Welder Join?

Theh SonoWeld system joins similar and dissimilar nonferrous metals, including aluminum, copper, nickel, silver, gold, brass, copper-to-aluminum assemblies, tinned and oxidized materials. Final weld capability depends on the materials, thicknesses, part geometry and tooling. Sonobond can evaluate your components and produce a free sample weld to determine the appropriate equipment and process settings.

Ultrasonic Spot-Welding Applications

The SonoWeld ultrasonic spot welder supports a wide range of industrial applications.

Battery Foils, Tabs and Terminals

It can weld multiple layers of delicate anode and cathode foils to battery tabs and terminals. It can join foils as thin as seven microns without tearing, making it well suited for lithium-ion and nickel-metal hydride battery production.

Wire-to-Terminal Welding

It can join stranded wires to terminals in a single pulse. It can also weld up to 10 stranded wires from a flat flexible circuit to multiple-connection terminals. The solid-state process creates a direct metallurgical bond without solder, flux or filler materials.

Sheet-Metal and Component Spot Welding

The ultrasonic spot welder can join thin sheets, foils, tabs and other nonferrous metal components. It is especially useful when conventional resistance welding could create too much heat or when the application requires dissimilar-metal joining.

Microprocessor Control for Repeatable Weld Quality

The SonoWeld system’s microprocessor controller allows operators to store and recall up to 250 weld protocols. Saved recipes help maintain repeatable settings when production changes between parts or assemblies.

The controller can monitor welding variables and identify conditions outside predetermined limits. Depending on the system configuration, these capabilities include:

Welding by time, energy or height
Monitoring power and weld time
Automatic frequency control
Overload protection
Incorrect-part detection
No-part detection
Pre-weld and post-weld height measurement
Weld-data transfer

These controls help manufacturers improve process repeatability, reduce operator-dependent variation and identify potential quality problems during production.

Advanced HMI With Smart Touchscreen

The optional Advanced HMI provides intuitive touchscreen control and expanded process monitoring. Operators can select welding modes, manage weld protocols and review production data from a centralized interface.

Pre-weld and post-weld height measurements are available when the SonoWeld is equipped with the Advanced HMI.