WeldMAX™ Ultrasonic Spot Welder

The WeldMAX ultrasonic spot welder is the industry’s most powerful system, delivering up to 10,000 watts of output power to weld a wide range of metal assemblies.

It produces ultra-reliable, solid-state metallurgical bonds without the use of heat, current, fluxes, filler materials or other consumables. It creates a welded joint that is strong and highly conductive. While welding rates vary with the thickness and type of materials being joined, most welds are completed in under three seconds.

WeldMAX welders use a solid-state frequency converter, a welding head, Sonobond’s unique Wedge-Reed system, and an easily removable and replaceable Taper Lock Tip that vibrates to create precise ultrasonic spot welds. Sonobond also offers custom-designed tooling tailored to each customer’s specific requirements.

Applications
The WeldMAX ultrasonic welder is used for heavy gage wire to wire, or wire to terminal assembly, electrical bus bar fabrication and other electronic/electrical assemblies even tinned stranded wire assemblies.

Theory of Operation
The WeldMAX spot welder uses Sonobond’s unique Wedge-Reed coupling system of high vibratory force and low amplitude to ensure precise, dependable welds. The unit directs high frequency, ultrasonic energy via a welding tip to the surface between the metals to be welded. The vibratory energy disperses the oxides and surface films between the workpieces and creates a true metallurgical weld without melting the materials.

Materials
The WeldMAX spot welder can be tooled to join stranded copper wire to wire up to 200 sq. mm. cross sectional area or equivalent weld area for stranded copper wire to terminal.