Ultrasonic Dual-Head Welder Achieves High-Strength Welding of High Voltage Terminals Without Causing Fracturing

WEST CHESTER, Pennsylvania—Automotive component manufacturers now have a reliable, environmentally friendly and cost-effective solution for assembling high-voltage terminals used for storage in electric and hybrid vehicles.

Sonobond Ultrasonics’ Dual Head Spot Welder, equipped with special tooling, can weld heavy wires up to 80 sq. mm. cross sectional area without fracturing the terminal.  Additionally, it achieves a higher-strength weld using lower power than other ultrasonic welders, and a more durable weld than crimp or solder methods.

Designing an Assembly Solution

As an example, Devine notes that a leading international automotive component manufacturer was getting a high percentage of cracked terminals when using a competitor’s 5000-watt ultrasonicwelder for assembly.  The damaged terminals had to be scrapped.

Advantages of Sonobond Ultrasonic Technology

Sonobond’s ultrasonic metal welders require no external heat, fluxes or fillers and produce no arcs, sparks or flames.  Instead, welding occurs by employing the company’s unique, patented Wedge-Reed ultrasonic bonding system that combines high vibratory force and low-amplitude coupling.  Shear mode vibration is applied parallel to the welding surface, while the line of force is directly over the parts to be welded.  This eliminates bending stress and creates consistent, solid-state, highly conductive, metallurgical welds. It also provides the unique ability to weld lightly tinned and oxidized non-ferrous metals, even without pre-cleaning.

Distinctive Features of the Dual Head Spot Welder

The Dual Head Spot Welder is the first ultrasonic welder to join up to 100 layers of copper or aluminum foil to battery terminals without tearing and in just one pulse, along with its capacity to weld wire bundles up to 80 sq. mm. cross sectional area toterminals.  It has a digital display that allows weld control by time, energy or (optional) distance.  Additionally, the unit has a power supply with a built in microprocessor, featuring automatic frequency overload protection, and storage and recall of up to 250 protocols.  Sonobond’s Dual Head Spot Welder also comes equipped with heat-treated tool steel Taper Lock Tips.  They can perform up to 30,000 welds before redressing and as many as 100,000 welds before replacement.  

Metal Welding Viability Test Without Obligation

Sonobond conducts a free, no-obligation metal welding viability test for all potential customers to ensure that ultrasonic welding technology is a good fit and to choose the welder best suited to handle their specific part configuration.  This gives Sonobond technicians an opportunity to recommend the best equipment for the job and show outcomes to customers.

Companies may arrange for an ultrasonic metal welding viability test by visiting Sonobond’s website at www.SonobondUltrasonics.com