For engineers faced with the task of joining nonferrous metals, stranded
wire, and many metal alloys, ultrasonic welding is emerging as an option to
It's a cold-phase friction-welding technique that requires no melting, and no
high temperature buildup of any kind.
To explain the process and illustrate applications where it works best,
engineers at STAPLA (Frankfurt, Germany and Wilmington, MA) decided to write a
book on the technology. Afterall, they figured, they were the first to design
and build an ultrasonic metal welding system, so who better to write the book on
The book describes an ideal metal-welding unit, including the generator,
welding device, transducer system, anvil, and fixtures. And, it discusses
certain welding parameters, such as the influence of welding energy, mechanical
stress, and thermal stress. It covers ways to improve the quality of the welds,
and discusses the materials suitable for ultrasonic welding.
According to STAPLA, The process applies high-frequency mechanical
oscillations to the surfaces being joined, rubbing them together under pressure.
The molecules of the surface begin to swirl and intermingle, creating a firm
Besides the book, the company, of course, also designs several
ultrasonic-welding products for use in industries such as automotive, appliance,
communications, and electronics. Among the latest is the Ultraindexer, which
STAPLA calls a precision ultrasonic welder coupled with a linear table.
Engineers can program the Ultraindexer to perform multiple weld cycles on the
same part or different assemblies.
Sonics & Materials, of Newtown, CT, also designs and manufactures
ultrasonic welding equipment. Among their most recent products: the Model 2050
20kHz Ultrasonic Rigid Welder. Its rigidity makes it suitable for demanding
applications where minimal deflection is important, the company says. The model
has THK rails and bearings, increased throat depth and increased column diameter
and wall thickness.
For more information, see www.staplaultrasonics.com
Sonics Model 2050 Ultrasonic Rigid