High-Frequency Ultrasonic Metal Welding
A joining process using high-frequency mechanical vibrations under static pressure, bonding thin sheets and foils without thermal overload.
In ultrasonic welding, the parts are held together under pressure and subjected to high-frequency vibrations. The friction between the joint surfaces generates heat and breaks up the oxide layer, so the metals weld directly together – without a molten pool. This process is especially suitable for thin sheets, foils, and different material combinations. You must ensure the surfaces are clean and free of grease, otherwise the joint won't hold. Also, the contact pressure and vibration duration must match the material – too little pressure and the sonotrode slips, too much and the sheet tears or gets squeezed too thin. If the settings are right, you get a clean, strong joint without thermal distortion. If the parameters are wrong, you'll notice it immediately from poor adhesion or cracks in the joint area.