Ultrasonic welding is a solid-state welding process for the permanent joining of nonferrous metals, e.g., copper or aluminium.
Ultrasonic metal welding is commonly used for the assembly of Lithium-ion battery systems of pouch type, wire harness and wire terminal or various other applications, such as electrical connections on ceramic substrates.
Some scientific literature highlights ultrasonic welding as the most common joining technique, which is considered proven and reliable. One of the advantages is joining of dissimilar materials, solid-state process, no need for filter metals or gases, low energy consumption and fast process and a perfect use for thin sheets, wires, or multi-layer sheets.
Ultrasonic metal welding is therefore mainly used for battery applications as well as automotive, electrical, and electronics industries. Nowadays, there is increasing use of sensors and camera systems which are finding their way into modern motor vehicles. Ultrasonic metal welding is in the automotive industry mostly used for connecting individual strands to each other or to a terminal.