ultrasonic metal welder manufacturer
- 15 Years+ Proven Industry Experience
- Smart Welding Integrity Monitoring (SWIM™)
- Fast welding, high strength, clean, and low resistance
Intelligent Inspection: Event-Driven QC + Automatic Monitoring Alarm
Ultrasonic Metal Welding Machine
Hyusonic manufactures ultrasonic metal welding machines, ultrasonic metal wire splicers, ultrasonic spot welding machines, ultrasonic metal tube sealing machines, etc. These machines can be used for welding non-ferrous metal wire harnesses, metal foils, soft pack batteries, terminal welding, and other applications. The full series adopts a modular design and can be customized into desktop models or tabletop models, and even integrated into automated equipment.
Advantages of Hyusonic Ultrasonic Metal Welding Machine
HYUSONICS ultrasonic metal welders utilize high-frequency vibrations (20-40kHz) to create solid-state bonds for copper, aluminum, and specialty alloys—without melting or external heat. Ideal for electric vehicle (EV) batteries, microelectronics, and precision wire harness manufacturing.
Optional Configurations
- Servo-Driven Precision Control
- MES Integration (Industry 4.0 Ready)
- Automated Load/Unload Systems
- Vision-Based Inspection & Recognition
Intelligent Ultrasonic Metal Welder iQ Series
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European Imported Ultrasonic Components
It adopts German imported circuit board components and rigid joint connection to achieve high-precision control and stability. -
Full-Series Modular Design
Scalable configurations for diverse production needs. -
CE & ISO 9001 Certified
Compliant with EU safety standards and international quality management. -
6 Welding Modes & 4 Trigger Modes
Programmable logic for complex applications (Time/Energy/Peak Power/Absolute Distance/Relative Distance/Ground Detect modes). -
Real-Time Monitoring & Quality Control
Dynamic data tracking (pressure/power/displacement) with automated fault alerts.
application video
Why Choose Our Ultrasonic Metal Welder?
✔ Oxide-Free Joints – Vibration removes surface oxides, achieving 500+ MPa tensile strength
✔ Energy Efficient – 60% lower power consumption vs laser welding
✔ Material Versatility – Weld dissimilar metals (Cu-Al, Ni-Ti) with <5% resistance increase
✔ Industry 4.0 Ready – PLC controls with Ethernet/IP, MQTT, or OPC UA protocols
Your satisfaction is our goal
Professional Ultrasonic Metal Welder Manufacturer
Key Applications of ultrasonic metal welder
| Industry | Typical Welds | Technical Advantage |
|---|---|---|
| EV Batteries | Tab-to-busbar, Foil stacking | No thermal damage to Li-ion cells |
| Electronics | Sensor pins, RFID antenna coils | 0.01mm precision, no flux residue |
| Automotive | Wire harness terminations | Vibration-resistant (compliant with LV214 standard) |
Our Exhibitions
What Our Clients Say
Customer FAQs
How does ultrasonic metal welding work compared to laser welding?
Ultrasonic metal welding uses high-frequency vibrations (20-40kHz) to create solid-state bonds without melting, while laser welding melts materials. Key differences:
✔ No heat distortion – Ideal for battery tabs & sensitive electronics
✔ Lower energy cost – 60% less power than laser
✔ Material flexibility – Bonds dissimilar metals (Cu-Al, Ni-Ti) components: generator, transducer, and horn.
Can you weld copper to aluminum with ultrasonic welding?
Yes! Ultrasonic welding is the preferred method for Cu-Al bonds in EV batteries and wire harnesses. Benefits:
✔ Oxide-free joints – Vibration removes surface oxides
✔ Low resistance – <5% increase vs. 20% with soldering
✔ No filler material – Pure metal-to-metal bonding
Is ultrasonic metal welding suitable for EV battery manufacturing?
Absolutely. Used by Tesla, CATL, and BYD for:
• Tab-to-busbar connections (0.2s/weld, 500+ MPa strength)
• Foil stacking – Up to 0.05mm thin layers
• No thermal damage – Preserves electrolyte integrity
What frequency is best for ultrasonic metal welding?
Depends on material thickness:
• 20kHz – Thick joints (>1mm) like busbars
• 30kHz – Foils (0.01-1mm) for batteries
• 40kHz – Micro-welds (<0.Z1mm) in electronics
How to test the strength of ultrasonic metal welds?
Industry-standard methods:
1️⃣ Peel test – Measures interfacial strength
2️⃣ Cross-section analysis – Checks bond penetration
3️⃣ Resistance measurement – Critical for electrical parts
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