Ultrasonic metal welding

Precise and reliable metal joints with ultrasonic technology

Ultrasonic metal welding joins metal components under pressure using high-frequency mechanical vibrations. The process creates a solid-state bond without fully melting the materials.

It is particularly suitable for joining non-ferrous metals such as copper and aluminium, as well as combinations of different materials. Ultrasonic metal welding enables fast, precise and energy-efficient joining processes with excellent electrical and mechanical joint quality

How does ultrasonic metal welding work?

During ultrasonic metal welding, the metal parts to be joined are positioned between a sonotrode and an anvil and held under a defined pressure. The sonotrode transfers high-frequency mechanical vibrations to the components. The relative movement between the contact surfaces breaks up existing oxide layers and surface films. At the same time, the components undergo local plastic deformation. The combined effect of pressure and ultrasonic vibrations creates a permanent solid-state bond.

The heat generated during the process remains concentrated in the joining zone and stays well below the melting temperature of the materials. As a result, the material structure is only minimally affected. The process enables repeatable joints, short cycle times and low energy consumption.

Advantages

• High electrical conductivity: Solid-state joints provide excellent electrical conductivity.
• Short cycle times: Metal joints can be produced in very short cycle times.
• Low heat input: The joint is created without extensive melting of the components.
• High process reliability: Defined and monitored process parameters support consistent, repeatable results.
• Energy-efficient: Energy is applied precisely to the joining zone.
• No additional materials required: Solder, adhesives and other joining materials can be eliminated.
• Joining dissimilar metals: Depending on the application, different non-ferrous metals can be joined together.

Applications

• Cable and wire-strand splicing
• Cable lugs and terminals
• High-voltage connections
• Busbars and power distribution bars
• Battery components and battery connections
• Copper-to-aluminium conductor joining
• Power electronics
• Electrical contacts and connection components

Ultrasonic metal welding is used wherever reliable electrical and mechanical connections are required with short cycle times. It offers an effective alternative to conventional joining technologies, particularly in the automotive, battery and electrical industries.

 

Materials

The process is particularly suitable for non-ferrous metals such as:

• Copper
• Aluminium
• Nickel
• Coated metal surfaces

Depending on the material, geometry and application, combinations of different materials may also be possible.

 

Ultrasonic metal welding with SONOTRONIC

SONOTRONIC develops and implements ultrasonic solutions for industrial joining applications, ranging from individual components to customised systems and automated production lines.
Together with our partners, we develop solutions for a wide range of applications in cable processing, electrical engineering, automotive manufacturing and other future-oriented industries.
Our focus is on application-specific system design, including the ultrasonic system, sonotrode and anvil, as well as reliable integration into the production process.

 

SONOTRONIC solutions for ultrasonic metal processing

SONOTRONIC offers compact ultrasonic solutions for a variety of electrical connection and cable-processing applications. The iSONIC ECO CUBE product family includes systems for welding, sealing, cutting and compacting metal conductors and components.

Technologies

Ultrasonic welding Ultrasonic cut & seal Ultrasonic roll seam welding Ultrasonic punching Ultrasonic cutting Ultrasonic embossing US thermofixing Ultrasonic washing Ultrasonic disintegration

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