Ultrasonic Metal Welding Equipments
1. Automatic frequency tracking: real-time frequency tracking,higher welding efficiency;
2. Amplitude adjustment: adapt to different welding requirements;
3. HMI human-computer interaction: simple and easy to understand operation;
4. Welding mode: Time, energy welding mode, suitable for different welding requirements;
5. Quality controlt: Provide complete data for high-quality welding and support data export;
6. Modular design: easy to debug, easy to maintain and upkeep.
Product Description:
Ultrasonic metal welding equipments are specialized machines that use high-frequency mechanical vibrations to join metal materials without melting them. Unlike traditional welding methods that rely on heat, this process applies controlled ultrasonic energy under pressure to create a solid-state bond between metal surfaces. It is particularly effective for welding non-ferrous metals such as copper, aluminum, nickel, and gold. Common applications include battery tab welding in electric vehicle production, wire harnesses, and electrical contacts. The technology offers key advantages, including low energy consumption, no filler materials, minimal heat generation, and strong, reliable welds with excellent electrical conductivity.
Parameter of Ultrasonic Metal Welding Equipments
| Product model | L40-P800 | L20-P2000 | L20-P4500 |
| Power supply | Single phase AC220V/AC110V switchable 50Hz | Single phase AC220V/AC110V switchable 50Hz | Single phase AC220V/AC110V switchable 50Hz |
| Air supply | Compressed air 0.1-0.6MPa | Compressed air 0.1-0.6MPa | Compressed air 0.1-0.6MPa |
| Ultrasonic peak power(W) | 800 | 2000 | 4500 |
| Maximum power of the machine(W) | 1000 | 2000 | 4500 |
| Ultrasonic frequency(KHz) | 40 | 20 | 20 |
| Maximum ultrasound time(s) | 0.4s | 0.4s | 0.4s |
| Adjustable accuracy of ultrasound time(s) | 0.01s | 0.01s | 0.01s |
| Ultrasonic mold connection thread size | M8*1.25 | 1/2*20UNF | 1/2*20UNF |
| Data output | Can export each welding data from an external USB drive | Can export each welding data from an external USB drive | Can export each welding data from an external USB drive |
| Upper mold size(mm) | 4×4 | 4×4 8×4 | 12×4 8×4 |
| Bottom mold size | 20×20 quick disassemble and replaceable | 20×20 quick disassemble and replaceable | 20×20 quick disassemble and replaceable |
| Maximum number of welding layers | 20 layers of copper foil (negative electrode) 20 layers of aluminum foil (positive electrode) | 30 layers of copper foil (negative electrode) 30 layers of aluminum foil (positive electrode) | 60 layers of copper foil (negative electrode) 60 layers of aluminum foil (positive electrode) |
Features of Ultrasonic Metal Welding Equipments
1. Solid-state, low-temperature welding: the base material does not melt, resulting in minimal thermal damage to heat-sensitive components.
2. Capable of welding dissimilar non-ferrous metals, including copper, aluminum, nickel, silver, and plated metals.
3. Requires no solder, flux, or shielding gas, resulting in low operating costs.
4. The weld joint exhibits extremely low internal resistance and excellent electrical conductivity.
5. Rapid welding speed: single-point welding takes only 0.1–2 seconds, ensuring high production efficiency.
6. Features digital automatic frequency tracking technology; both welding time and pressure are adjustable, making it suitable for a wide variety of workpieces.
7. The welding process generates no sparks or fumes; it is environmentally friendly and pollution-free, complying with global workshop operational standards.
Application:
1.Electric vehicle (EV) battery manufacturing: Welding battery tabs, busbars, and terminal connections in lithium-ion battery packs.
2.Automotive industry: Joining wire harnesses, airbag igniters, and other electrical components.
3.Consumer electronics: Assembling batteries for mobile phones, laptops, and power tools.
4.Electrical and electronic components: Welding relays, switches, capacitors, and connectors.
5.Solar energy industry: Connecting photovoltaic cells and tabbing ribbons in solar panel production.
6.Medical devices: Manufacturing pacemakers, defibrillators, and other implantable or sensitive electronic medical equipment.
7.Aerospace and defense: Producing lightweight, high-reliability electrical interconnections.
8.Wire and cable processing: Splicing, terminating, or tinning wires without melting the insulation.
9.Battery recycling: Separating or cutting metal tabs during battery disassembly.
10.General metal joining: Bonding non-ferrous metals such as copper, aluminum, nickel, brass, and gold for various industrial applications.
FAQ:
How do I choose between different frequencies (20kHz and 40kHz)?
Answer: Frequency determines the amplitude and nature of the weld .
Lower Frequencies (20kHz): Higher power, deeper penetration. Suitable for larger, thicker parts, or materials with higher hardness (e.g., thick busbars) .
Higher Frequencies (40kHz): Lower power, higher precision. Suitable for small, thin, or sensitive components (e.g., fine wires, small battery tabs, medical devices). Higher frequencies also cause less surface marking .
Is welding performed without consumables?
Yes. Ultrasonic metal spot welding is a consumable-free welding process. It does not require solder, flux, adhesives, filler materials, or shielding gases. The welding is achieved through high-frequency ultrasonic vibrations combined with pressure, creating a solid-state bond between the metal surfaces. This results in a clean, environmentally friendly process with low operating costs and minimal material waste. The only routine maintenance items are the welding horn and tooling, which have a long service life under normal operating conditions.
About Us
We are a professional Chinese manufacturer specializing in R&D, production and sales of industrial ultrasonic equipment, mainly including ultrasonic metal welding equipments, wire splicing welders and industrial ultrasonic welders. Our core R&D team has rich experience in ultrasonic technology, equipped with independent digital frequency-conversion circuit design and precision processing workshop. All machines pass CE certification and comply with international industrial production standards.
We support customized welding horns and non-standard equipment development according to customers' workpiece requirements, serving lithium battery, new energy vehicle harness, 3C electronics and precision hardware industries worldwide. With strict quality inspection system and complete after-sales service, we have exported products to many countries and become a reliable long-term ultrasonic solution supplier for global manufacturers.
Our Services for Global Customers
We provide one-stop professional services for all overseas clients, including customized product solution design, free welding process testing, and custom welding horn development. All our machines support OEM and ODM services to meet different industrial production requirements.
We offer comprehensive pre-sale technical consultation, detailed parameter selection guidance, and professional after-sale support such as operation training, remote debugging, and lifetime technical support. Fast delivery, stable quality inspection, and complete export documents ensure smooth and worry-free cooperation for global customers.
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