If you are not using ultrasonic metal welders, then you simply can not afford not to look into it.

Send us your material for evaluation at no cost. We will send the welded parts back with a comprehensive report.

The Application:

Since dissimilar metals are frequently used in the manufacturing of batteries and capacitors, ultrasonic welding is the ideal joining technique. Materials that are readily welded in any combination by ultrasonics include:

Aluminum Copper Gold

Lithium Nickel Brass

Silver Platinum Zinc

The above mentioned material can be welded in various forms, for example:

• Nickel tabs to copper and aluminum foil.
• Nickel tabs to nickel, foam, or felt.
• Nickel tabs to lithium battery caps.
• Aluminum tabs to aluminum foil and aluminum mesh.
• Copper tabs to copper mesh.

• The high frequency vibrations remove the oxides instantly and a true metal to metal contact is established.
• There is practically no measurable heat generated at the joint; therefore, the integrity and the electrical conductivity of the material is preserved.
• The process is very gentle and forgiving on finer material (i.e. foils).
• Continuous uninterrupted seam welds are readily performed.

The Equipment:

• Quality monitoring is built into every system; therefore, the consistency of the process can easily be controlled.
• Weld cycles are typically under one-half second and the process is often automated.
• Tooling can be custom designed to provide maximum contact between the material.
• Tool life is considerably longer in comparison to conventional welding techniques.
• The welders can easily be integrated into inert environments.

In short, using ultrasonics in battery manufacturing will translate into better quality, higher productivity, and lower cost.

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