Sonic Welding

Sonic or ultrasonic welding (USW) is a process in which strong frictional heat is generated at the portions of parts to be welded by simultaneously applying pressure and ultrasonic vibration to melt and weld these portions. Although many materials can be ultrasonically bonded, the easiest to weld are aluminum and copper alloys. Typical applications include foil welding in aluminum and copper mills, wire-to-wire terminations, tube-to-sheet welding for solar panels, power transformer wire terminations, field coils, motor armatures, brush-wire terminal attachments, and many thermoplastics and nonferrous metals.


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