Ultrasonic Metal Welding
A pressure welding process utilizing high-frequency mechanical vibrations to disrupt oxides and bond components through solid-state friction. It is predominantly used in electrical engineering for fine conductors.
Ultrasonic welding joins metals using high-frequency mechanical vibrations that break up the oxide layer and weld the parts together through friction heat and pressure. You don't need filler materials or high temperatures; the process is well suited for thin sheets, foils, or stranded wires. The settings for vibration amplitude, pressure, and weld time must match the material and part geometry – too much energy makes the joint brittle, too little won't hold. Make sure the sonotrode is clean and the parts are properly positioned, then you'll get a clean, strong connection.