Ultrasonic Metal Welding
Ultrasonic Metal Welding
Ultrasonic metal welding is a solid-state joining technology in which ultrasonic vibration is applied while two metal components are pressed together under controlled pressure. When ultrasonic vibration is introduced, microscopic frictional motion occurs at the joint interface. This motion breaks down surface oxides and brings the metals into intimate contact, allowing pressure and frictional energy to work together to promote atomic diffusion and form a strong metallurgical bond. Because this process does not require soldering or melting, it minimizes thermal impact and achieves highly reliable joints with low electrical resistance.
Ultrasonic metal welding is widely used for joining metal components that are sensitive to heat or require high electrical conductivity, such as automotive electronics, electronic components, motors, secondary batteries, and wire harnesses. It is particularly effective for joining dissimilar metals such as aluminum, copper, and nickel, and can also be applied to components where soldering is not feasible or to insulated and coated wires. By eliminating high-temperature processes, ultrasonic metal welding serves as an efficient alternative technology in production lines for EVs, batteries, motors, and sensors.
Application Examples
Automotive industry
Metal welding of steering wheel motor harnesses
Electronics & automotive electronics
Metal welding of wire harnesses
