Principles of Ultrasonic Metal Welding

The principle of ultrasonic metal welding is a special method that uses mechanical vibration energy at ultrasonic frequencies (above 16KHz) to join the same or different metals. When metals undergo ultrasonic welding, neither current is delivered to the workpieces nor high-temperature heat sources are applied. Instead, under static pressure, the vibration energy of the wire frame is transformed into frictional work, deformation energy and a limited temperature rise between the workpieces. Metallurgical bonding between joints is a solid-state welding achieved without melting the base metal. Therefore, it effectively overcomes phenomena such as spatter and oxidation that occur during resistance welding. Ultrasonic metal welders can perform single-point welding, multi-point welding and short strip welding on fine wires or thin sheets of non-ferrous metals such as copper, silver, aluminum and nickel. It can be widely applied to the welding of thyristor leads, fuse plates, electrical leads, lithium battery electrode plates and tabs.