1. What is Ultrasonic Metal Welding?
Ultrasonic metal welding is a “cold welding” that does not melt the metal. It uses ultrasonic vibration to produce frictional motion between metals. The heat generated by friction quickly removes the oxide layer of metals (especially non-ferrous metals). Under the action of pressure, it accelerates the movement of molecules and forms interconnections.
The characteristics of high frequency (20–40Khz) and low amplitude vibration of ultrasonic waves are used to create intermolecular connections between metals.
2. Application of Ultrasonic Metal Welding
There are many applications for this technology, especially in those industry sectors that use complex, delicate, or tiny parts.
New Energy Vehicle Industry. The tabs on the lithium battery pack of electric vehicles that are popular now, as well as the welding of wiring harnesses and wiring harnesses inside the car, and the welding of wiring harnesses and terminals. These welding materials tend to be copper or aluminum with high electrical conductivity, so traditional resistance welding is not possible. In addition, ultrasonic metal welding has a small heat-affected area, making it a very safe welding process.
Medical Industry. The most typical application is pin soldering on integrated circuits in medical devices. No glue or adhesive is required for the process. Examples include pacemakers used to treat patients and sensors implanted in the body. Ultrasonic welding is also widely used in the manufacture of intravenous catheters, blood/gas filters, dialysis machines, valves, and filters.
Electronics and Computer Industry. Ultrasonic welding is the best connection process for wires and circuits on microelectronic components, which is used in chips, motors, capacitors, flash memory, microprocessors, transformers and other products. The entire welding process welds a thin metal (usually aluminum or copper) with a thick material to seamlessly connect wires and circuits. It can effortlessly connect circuits on a circuit board, making it ideal for the smartphone and computer industries.
Aerospace industry. In the manufacture of engine parts, non-ferrous metal materials such as aluminum are welded to steel, and the components after welding have high drawing strength, accurate dimensions and beautiful appearance. It also meets the requirements for sealing performance and impact resistance of the closed chamber after welding.
Refrigeration industry. Copper pipes have been used as cooling system components for refrigerators and air conditioners. Since copper materials are expensive, aluminum tubes have also begun to be used instead. But regardless of whether copper pipes or aluminum pipes are used, ultrasonic can be used for sheet welding or sealing.
Ultrasonic welding results in high-quality products and is a proven very reliable joining technique. In the future, ultrasonic welding is expected to drive market growth in more industrial applications.
