Principle of ultrasonic metal welding:
The principle of ultrasonic metal welding is a unique method of connecting the same or different metals together by using the mechanical vibration energy of ultrasonic frequency (usually more than 16KHz). During the welding process, the metal workpiece will not be affected by electric current or high-temperature heat source. Only under static pressure, the vibration energy is converted into friction, deformation and limited temperature rise between the workpieces.
This metallurgical bonding is a solid-state welding achieved in the state where the parent material is not melted, thus effectively avoiding the spatter and oxidation problems during resistance welding. Ultrasonic metal welding machines are suitable for thin wires or thin sheets of non-ferrous metals such as copper, silver, aluminum, and nickel. They support single-point, multi-point and short strip welding, and are widely used in the welding of thyristor leads, fuse plates, electrical leads, lithium battery pole pieces and pole ears.
01 The many benefits of ultrasonic metal welding include:
- a. The material does not melt during welding, thus maintaining the metal’s strong properties.
- b. After welding, the conductivity is excellent and the resistivity is almost zero.
- c. The technology does not require high surface treatment of the metal, and both oxidized and electroplated metal surfaces can be welded.
- d. The welding time is short and efficient, and no flux, gas or solder is required.
- e. No sparks are generated during the entire welding process, ensuring environmental protection and safety.
02 Application:
- 1) In nickel-hydrogen batteries, nickel mesh and nickel sheet can be ultrasonically welded.
- 2) In the production of lithium batteries and polymer batteries, copper foil and nickel sheet, aluminum foil and aluminum sheet can be mutually melted by ultrasonic welding.
- 3) When wires are mutually melted, whether it is a single wire or multiple wires, welding can be completed conveniently.
- 4) In the process of connecting electronic components, wires and contacts and connectors can also be firmly connected by ultrasonic welding.
- 5) For high-current contacts such as electromagnetic switches and fuseless switches, the mutual melting of dissimilar metal sheets can also be completed by ultrasonic welding.
- 6) The sealing and cutting operations of metal tubes can achieve a perfect combination of water and air tightness.
Ultrasonic Metal Welding Machine Metal Spot Welder Machine Supplier
- Power adjustable, operate simple, and run stable and reliable.
- Touch screen display keeps the machine visible in operation and regulation.
- Heavy duty linear bearings assure precision motion and no flash.
- Overcurrent protection and soft start can keep the machine safe.
- Not only similar metal, but also dissimilar all can welding together. it can weld metal slice or sleeve to thick metal. Usually used for transistor or IC’s leads welding.
03 Application Prospects
Automotive industry: Ultrasonic welding technology plays an important role in automobile manufacturing. It can be precisely controlled by computer programs to achieve welding of large and irregular workpieces, such as bumpers, doors, lamps, and brake lights. In addition, with the popularization of highways, the demand for ultrasonic welding of reflectors is also growing. It is worth mentioning that the new energy vehicle industry, such as the battery field, has also begun to widely adopt this technology.
Toy manufacturing: Ultrasonic technology brings a clean, efficient and strong production method to toy manufacturing, eliminating the need for auxiliary products such as screws and adhesives, reducing production costs and improving market competitiveness.
Electronics industry: Ultrasonic welding technology has important applications in the electronics industry. Through the design of automated solutions, large-scale production can be achieved while ensuring product quality.
Other commercial uses: Ultrasonic equipment is also widely used in industries such as communications equipment, computers, printing equipment, and audio-visual products, providing users with simple, clean, and efficient production methods and expanding business opportunities.
04 Future
Ultrasonic metal welding technology is moving towards a smarter, more flexible and more sustainable direction. Xiaowei will continue to provide innovative solutions for advanced manufacturing.
The rapid expansion of the electric vehicle market has significantly driven the demand for ultrasonic welding machines, while strict environmental regulations and the growth of renewable energy have also driven the application of ultrasonic welding technology.
Ultrasonic metal welding machines have performed well in terms of market size, technological progress and application areas, and will continue to benefit from demand growth and technological progress in multiple industries in the future.
