Applications of the ultrasonic metal welding machine

Table of Contents

Metals suitble for ultrasonic metal welding

Ultrasonic metal welding can be used with copper, aluminium, nickel, silver, and gold.

The metal workpieces to be weld is mainly in the shape of fine wire or thin layer. The welding thickness should not exceed 4 mm and the welding area, not exceed 50 mm². The operation includes single-point welding, multi-point welding and discontinuous welding. Ultrasonic metal welding is time-saving and highly cost-efficient. The cycle times are typically less than a half second.

Ultrasonic metal welding is commonly used to weld thyristor leads, fuse pieces, electrical leads, lithium battery pole pieces, pole lugs.

Diagram of welding possibilities between metals

Applications of ultrasonic metal welding

Tooth patterns: (truncated) prismatic, hemispherical, linear

Whether the teeth are aligned?

The thickness of the workpieces (the thicker the workpieces is, the deeper grooves on the welding head is needed)

Thus, welding heads should be changed for different workpieces.

Application areas of ultrasonic metal welding machines


Welding copper foils is a typical application of ultrasonic welding in battery production. The copper foil to be welded is usually of 6 µm to 0.3 mm thickness. The number of foils layers that can be welded simultaneously varies from 2 to 160 layers. Application examples: square cells, soft pack cells and cylindrical cells.

For the NiMH battery, the nickel mesh is welded with the nickel sheet. For the lithium battery and the polymer battery, the copper foil is welded with the nickel sheet and the aluminum foil is welded with the aluminum sheet.

Battery terminals

Battery terminals are usually used to transmit high current loads hence should be made to endure high pressure and power. When welding two terminals, the maximum thickness of the terminal can reach 3 mm. The finished products are susually used in Battery management systems or high power contacts.

The circuit group and the terminal

Cables and connectors assembled by ultrasound have become indispensable in modern vehicles. The cable cross-sections range from 6 to 85 mm². The conductor materials used are copper and aluminium. One of the most common applications of the welded circuit group and terminal is the transmission of high power within a wire harness.

The tooth pattern of the welding head and base affects the quality of the welding and the stability of the process.

The electric wire

The electric wire is often welded with other wires, various electronic components, contacts, and connectors.


Weld the large heat sinks, heat exchange fins and honeycomb cores for various household appliances and automotive products. 

Weld electromagnetic switches, fuseless switches and other high current contacts, dissimilar metal sheets.

Weld the end of metal tube to prevent water and air.

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