Ultrasonic Metal welding systems are composed of the same basic elements:

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A Ultrasonic press to put the two parts to be ultrasonic assembled under pressure, the press can be:

to be able to have a controlled moment for the ultrasonic process, like Ultrasonic Metal Welding, Ultrasonic Metal Cutting, Solar panel welder Ultrasonic rotating metal welder ect. and are in 98% of the times used direct Horizontal on the part.

A ultrasonic nest or ultrasonic anvil where the parts are placed and allowing the high frequency ultrasonic vibration to be directed to the interfaces

An ultrasonic stack composed of a ultrasonic converter or ultrasonic piezoelectric transducer, an optional ultrasonic booster and a ultrasonic sonotrode, Horn.

All three elements of the ultrasonic stack are specifically tuned to resonate at the same exact ultrasonic frequency (Typically 15, 20, 25, 30, 35 or 40 kHz)

Converter: Converts the electrical signal into a mechanical ultrasonic vibration

Ultrasonic Booster: Modifies the amplitude of the vibration. It is also used in standard systems to clamp the ultrasonic stack in the ultrasonic press.

Ultrasonic Sonotrode – Horn: Applies the mechanical vibration to the parts to be welded.

An electronic ultrasonic generator (US: Power supply) delivering a high power AC signal with frequency matching the ultrasonic resonance frequency of the stack.

A controller controlling the movement of the press and the delivery of the ultrasonic energy.

Ultrasonic Metal Welding,
Ultraschall metall schweissen,
Soudage à ultrasons
Saldatura dei metalli ad ultrasuoni
超声波金属焊接
Spawanie ultradźwiękowe Metal
Soldagem ultra-sônica
Ультразвуковая сварка металлов
Soldadura de metales por ultrasonidos

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But all of the above names serves the same purpose,

Ultrasonic metal welding, composed of a ultrasonic converter or ultrasonic piezoelectric transducer, and the ultrasonic press

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Ultrasonic Metal wire splicer – bonder – welder Sonic power Weld 4010 – 40 kHz

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High quality German made Ultrasonic Metal spot Welder Equipment Including Ultrasonic Sealers, Ultrasonic Splicer’s, Welders and Seam welders

Our Ultrasonic spot welding system offers the following features:

• A precision roller bearing slide to assure smooth operation and extreme accuracy
• Delivering up to 1000 W of ultrasonic energy, 40 kHz Sonic Power Weld 4010 is suited for non-ferrous metal-joining applications, such as welding battery components or small gauge electrical wires and terminals. Measuring 4 x 5 x 12 in., unit has ½ wave reach of 12 mm and full wave reach of 115 mm. Total travel of actuator is 25 mm.
• Components are easily presented between horn and anvil for manual or automated welding.
• Sonic Power’s – Sonic Power Weld 4010 is a 40 kHz, linear ultrasonic metal welding system designed to be an economical solution for many nonferrous metal-joining applications System
• The Sonic Power Weld 4010 has been specifically engineered to provide precise linear actuation, and the precision application of 40 kHz, high power (up to 800 Watts) ultrasonic energy for critical, non-ferrous metal joining requirements. The Sonic Weld 4010 is ideally suited for welding battery components, or small gauge electrical wires and terminals
• The small size of the Sonic Power Weld 4010 (~ W 100, H 125, L 300) makes it easy to work with. The total travel (stroke) of the actuator is 25mm. The Sonic Weld 4010 has a ½ wave reach of 12 mm and a full wave reach of 115 mm. Components are easily presented between the horn and anvil for manual or automated welding.
• Sonic Power is a leading worldwide supplier of ultrasonic metal weld equipment, tooling and technology.

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Ultrasonic Metal spot welder from 15 kHz to 60 kHz

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High quality German made Ultrasonic Metal spot Welder Equipment Including Ultrasonic Sealers, Ultrasonic Splicers, Welders and Seam welders

Our Ultrasonic spot welding system offers the following features:

• A precision roller bearing slide to assure smooth operation and extreme accuracy
• A dynamic spring with preload adjustment to permit ramping of ultrasonic power for optimum ultrasonic metal welds
• Precise adjustments for accurate setting of both upper and lower positive stops conveniently located flow controls offering easy adjustment of head speed in both directions.
• A polar mounted ultrasonic stack to facilitate linear and axial setup and efficient transmission of ultrasonic energy to the ultrasonic horn
• Ultrasonic titanium horns with low cost replaceable tips or solid tool steel ultrasonic horns for fast setup and minimum tooling cost
• Fixturing which is changed quickly and easily for various applications by means of a dovetail mounting
• Optional vortex cooling to allow high-speed operation without heat buildup
• Optional our special designed water cooling system, for maximum production out put
• 20 kHz Ultrasonic spot welding System rugged and easily tooled for a wide range of nonferrous welding applications
• Power supply’s from 1000 watt to 5000 watt

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Ultrasonic metal welding wire splizer

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• Creates a true solid  bond with the lowest possible voltage drop, and minimal energy consumption
• Produces no arcs, sparks or fumes, and does not melt the wires
• Microprocessor controller welds by height, energy or time.
• Bonds wire bundles even if the wires are oxidized, or tinned coated
• 1500 and up to 5000 watt ultrasonic power supplies are available

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Ultrasonic Solar panel welder 20 kHz

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• True metal bonds provide excellent heat transfers.
• All mechanical process – no electrical current passes through the work piece and no melting occurs
• Ideal for welding copper or aluminium metals of varying thicknesses
• Lowest cost per ultrasonic weld compared to fusion methods for metal joining
• Superior tool life, do to our special material
• Welding variables can be precisely monitored and controlled.
• Energy efficient
• Easy to set up and operate
• The Sonic Seam so is the ultimate metal seam welder – ideal for continuous welding of aluminum and copper foils at speeds up to 20 meters per minute.

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Ultrasonic Seam Welder 50 kHz

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• Precision roller bearing slides to assure smooth operation and extreme accuracy
• System can quickly be configured to adapt to various applications.
• Precise adjustments for accurate setting of both upper and lower positive stops
• Conveniently located flow controls offering easy adjustment of head speed in both directions
• A polar mounted ultrasonic stack to facilitate setup and efficient transmission of ultrasonic energy to the ultrasonic horn
• Ultrasonic titanium horns with low cost replaceable tips, or solid tool steel ultrasonic horns, for fast setup and minimum tooling cost
• Increased head travel for ease of part loading and unloading.
• Super for welding of Lithion batteries.

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Ultrasonic Tube Welder / sealer, 20 kHz or our 25 kHz “Sound of Silence”

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• Ergonomic, light-weight design for operation on the assembly line
• Quick change tooling with multiple weld surfaces for low cost operation
• Automatic process monitoring ensures each seal falls within preset quality limits of weld power, time and final height
• Weld-to-height mode to compensate for tube material variations
• Various tube sizes may be sealed in any sequence through automatic setup of weld parameters
• RS232 port for computer interfacing
• Our Ultrasonic tube sealer is designed for ultrasonic weld and cut of the copper tubes at the same time, if so desired

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