Joint welding (ultrasonic)
Ultrasonic welding is a modern technology for joining wires,
guaranteeing low connection resistance, high durability and full process repeatability.
Ultrasonic welding technology
Ultrasonic welding is a process in which acoustic vibration energy is converted into frictional heat at the point of contact between the wires. This results in a durable, metallic connection without the need for flux, tin or solder.
This technology is ideal for applications where low contact resistance, stability of electrical parameters and high repeatability are important.
The process is carried out using modern Branson and Sonobond ultrasonic welders.
APPLICATIONS AND ADVANTAGES
Low resistance
An exceptionally low-resistance connection that ensures stable electrical parameters even after thousands of operating cycles.
Trwałość mechaniczna
The absence of inclusions and oxidised surfaces results in high resistance to vibrations, oscillations and material fatigue.
Process repeatability
Automatic control of welding parameters and recording of production data ensure consistent batch quality.
How we implement the process
Our machine park uses ultrasonic welding machines from global manufacturers. These devices enable precise adjustment of process parameters to the type of conductor and beam cross-section.
Shrinking
Branson 2032S
Ultrasonic welding machine designed for multi-wire connections and cables with large cross-sections. It enables software control of amplitude and pressure force, ensuring repeatability and safety of the process.
Sonobond WS 2026
Compact device for welding copper wires and cables. Used for precise connections with small cross-sections, with full control of process parameters.
Ultrasonic welding machines
- Frequency: 20–40 kHz
- Clamping force: adjustable according to the cable cross-section
- Welding time: 0.1–1.5 s
- Welding area: up to 40 mm²
- Possibility of documenting and archiving parameters
Weld quality control
Each weld is verified for connection resistance, geometric shape and mechanical strength. Samples are tested in a quality laboratory using microscopy and peel tests.
RELATED PROCESSES
Shrinking
Mechanical, pneumatic and hydraulic presses, clamping force control.
Whitewashing and soldering
Soldered connections and preparation of terminals for assembly – automatic machines and manual stations.
IDC
Connections without preliminary stripping – quick and economical.
Let us handle this process for you.
Take advantage of our offer covering this stage of production and receive full technological support.
Zgrzewanie ultradźwiękowe
Durable ultrasonic joints with low resistance and high mechanical strength.
Do you have the wiring documentation?
Do you require a low-resistance connection?
Choose ultrasonic welding – a precise, durable and fully controlled process for joining wires.