The right joining solution for your application
To ensure your success, we advise you at every step of the project with over 60 years of ultrasonic experience: from the first sketch to the development of the application to process optimization and beyond.
This will optimize your production with a safe joining process in combination with durable welding tools that are 100% Made in Germany.
The advantages of ultrasonic welding:
- High strength
- No losses in conductivity
- Short cycle times
- Particularly gentle on materials
- Permanent process monitoring
Unlock New Potentials – Ultrasonic Welding for Electrical Connections and Batteries
Watch our on-demand webinar to get the perfect start on optimizing your wire or battery production with ultrasonic welding.
Here is what you’ll learn:
- The secret behind the technology: How ultrasonic welding works
- Use cases: suitable applications and materials for ultrasonic welding
- Safe & reproducible: How ultrasonics ensures minimal rejects
OR
FAQ – The Most Important Questions and Answers about Welding Metals with Ultrasonics
Ultrasonics can be used to safely connect the same and different non-ferrous metals within a very short time. It is mainly used for the connection of conductive non-ferrous and precious metals. These include aluminum, silver, copper and nickel in particular, with aluminum-copper connections accounting for 90% of applications.
Weldable non-ferrous metals are all pure metals except iron as well as alloys (connections of different metals) that have less than 50 percent iron content. Pure ferrous metals cannot be joined with ultrasonics.
Due to the optimal conductivity of the connections and the short welding times, ultrasonic welding has established itself as a joining technology for numerous applications consisting of non-ferrous metals. These typically include:
- Lithium-ion battery (LIB)
- Pouch cells and flexible housings
- Battery management systems
- Wire-terminal
- High-voltage cable
- Busbar / terminal terminal
Find our application in our video.
Ultrasonic welding is a joining process without additional joining agents. Mechanical vibrations are created by an ultrasonic generator and converter. The welding tool, the so-called sonotrode, transfers these mechanical vibrations to the components.
One joining part vibrates in the longitudinal direction, while the other remains secured in the fixture. Friction breaks up the oxide layer and the parts are welded together at the same time under pressure.
The decisive factor in welding is not the heat generated, which is well below the melting point, but the relative movement of the two joining partners.
Learn more about ultrasonic welding in our webinar “Unlock New Potentials – Ultrasonic Welding for Electrical Connections and Batteries”.
Ultrasonic welding of metals has several advantages over conventional welding methods such as crimping or laser welding:
- Speed: The welding process with ultrasonics only takes fractions of a second.
- Reliability: The specification and monitoring of numerous welding parameters ensures precise and reproducible welding results. This is a decisive advantage, especially when welding sensitive and small metal parts, such as in batteries.
- Cost efficiency: Ultrasonic welding does not require any additional joining materials such as solder.
- Sustainability: Ultrasonics welding requires very little energy as it does not use heat to connect metals and does not require the use of chemical tools.
- Safety: Ultrasonic welding produces no sparks or smoke, which makes it safe to work in manufacturing.
- Gentle: Materials are not damaged or deformed outside the defined weld area.
Learn more about the benefits of ultrasonic welding in our webinar “Unlock New Potentials – Ultrasonic Welding for Electrical Connections and Batteries”.
When welding with ultrasonics, the ideal parameters are determined individually for each application via test series in the ultrasonic laboratory. These can be reproduced exactly thanks to the precise process control.
This ensures a safe, reliable process and minimizes scrap rates – and costs – over the long term.
Up to 150 different welding data can be recorded, saved and exported for each individual welding process. This monitoring is fully automated and ensures seamless digital quality control.
Another advantage of archiving the welding processes: each weld is assigned to a specific component, giving it its own digital fingerprint. This enables complete traceability.
For example, if a problem occurs with a battery cell later during use, it is possible to check exactly if the welding process was carried out according to the defined specifications or if deviations have occurred. In the case of deviations, other battery cells with the same deviations can also be identified.
Our experienced experts will be happy to show you the advantages of ultrasonic welding for your individual application.
Learn more about the benefits of ultrasonic welding in our webinar “Unlock New Potentials – Ultrasonic Welding for Electrical Connections and Batteries”.
Download Expert Resources
Discover new ways of welding your battery or wire-terminal application and learn more about our innovative technology! Our downloads contain the knowledge from over 60 years of ultrasonics, providing valuable insights into advanced assembly techniques. By sharing our technical knowledge with you, we ensure a close partnership on equal terms so that we can realize projects as quickly and successfully as possible.
Download our exclusive resources to stay ahead of your competition.
Welding battery cells sustainably with ultrasonics
"With Herrmann Ultraschall we have found a reliable partner in the area of safe welded joints at our side. Herrmann's ultrasonic equipment makes a significant contribution to improving our product quality. At Customcells, we highly value sustainability and energy efficiency and are therefore extremely satisfied with the excellent cooperation and the joint implementation of the latest technologies. We can recommend Hermann Ultraschall without any reservation."
Christian Zender, Director Customcells Tübingen GmbH
Boost your electrical connections with ultrasonics
Ultrasonics can offer you added value at every connection where electricity flows: Wire terminal applications benefit from strong connections without contact resistance and minimal process cycles. Batteries can be connected gently and with the lowest reject rates.
Discover the most common applications for ultrasonics welding and start your project now!
Partner with Us
Contact us to discover how our premium solutions can elevate the quality and effectiveness of your large-scale production in the metal industry. We look forward to hearing from you!
