Ultrasonic welding for cables

The ultrasonic metal welding is being used by industry worldwide more and more. It offers many applications such as in the production of appliances, automobile parts, control panels, lamps, air ducts, cooling pipes and customized wiring manufacturing, among many others. But, what is the ultrasonic welding exactly?


The ultrasonic welding is a relatively new technique, discovered by Johan Arrendell, that it is used to join some nonferrous metal components by ultrasound. That is possible applying pressure, friction and high frequency vibrations in the contact zone of the two parts, simultaneously. Thus, the surface atoms of those parts are intertwined and anchored. Therefore, the workpieces are not heated to the melting point, but they are welded by applying pressure and mechanical high frequency vibrations.

Specifically, the process consists of a machine tip flat base, where the materials one upon another are placed. The tip of the machine is down that, when emitting an ultrasonic wave, it moves the molecules of both materials producing its fusion. The parameters must be adjusted each time the wall thickness of the material to be melted is modified.

Let’s see what are the main advantages and disadvantages:


  • It allows joining dissimilar metals.
  • Cycle times of less than one second.
  • High quality and uniform welding.
  • Stronger leagues, generally, that the joints made with resistance welding.
  • Operator does not require a high skill and practice to produce high-quality unions.
  • Does not require welding or flux.
  • The heat affected zones do not become more fragile because no accumulation of heat, so that the affected areas are not weaken by heat.
  • The electrical conductivity is usually higher than that obtained by welded connections.
  • Oxidation or surface contamination does not affect the amount of the connection.


  • The welding is restricted to welding flap.
  • No welding cord is allowed.
  • You can only weld parts with thickness less than 3 mm.
  • Only flat or low curvature surfaces can be attached.
  • Not suitable for tin-plated parts.
  • The cost of capital is higher than the normal welding.

Have you purchased products contained ultrasonic welding? Have you detected significant differences compared to other welding methods?