Ultrasonic Metal Welding – metal bonds without consumables
The first patent ever issued for ultrasonic metal welding was awarded to Sonobond Ultrasonics (then known as Aeroprojects) in 1960.
Since then, the company has been the worldwide leader in the development of ultrasonic metal welding equipment.
Sonobond ultrasonic metal welders create precise, solid-state metallurgical bonds without heat, current, or consumables. This is accomplished by introducing high-frequency vibration while the weldment is under moderately high clamping force. In this way, non-ferrous similar and dissimilar metals can be welded with repeated accuracy.
Sonobond’s Unique “Wedge-Reed” Bonding System
Sonobond’s metal spot welders have an important advantage over other types of ultrasonic metal welding equipment because they use the unique, patented “Wedge-Reed” bonding system.
This system maximizes metal welding effectiveness by combining low vibratory amplitude with high vibratory force. Dependability is assured by utilizing shear mode vibration that is parallel to the welding surface. Bending stress is eliminated by positioning the line of force directly over the welding surface.
This bonding method permits the joining of thin-to-thin or thin-to-thick materials, including dissimilar metal joints. It produces joints with good thermal and electrical conductivity, while welding through most oxides and tinned metals. No special cleaning process is required.
A Wide Variety of Important Applications
Sonobond’s ultrasonic metal welders are used to weld stranded wire-to-wire and wire-to-terminal for applications such as electrical wire harnesses and bus bars.
They are used to weld the terminals of lithium-ion batteries, foil-wound capacitors, thin aluminum or copper foil, and electrical contacts. They play an important part in the manufacture of fuses/circuit breakers, ignition modules, starter motors, and photovoltaic panels. And Sonobond’s ultrasonic metal welders are also frequently used to close HVAC tubing, replacing crimp and solder methods.
