ULTRASONIC METAL WELDING FOR WIRE SPLICING AND TERMINATION by John Wnek
Ultrasonic energy has been shown to be a useful tool in a wide variety of applications from very low power medical diagnostics through high intensity processes which change the state of materials. Joining of metals, specifically nonferrous metals used in electrical connections, is a particularly useful application of this technology. Commonly used techniques involving the fusion of metal through the application of heat by flame, hot tools, electric current or electric arc in combination with cleaning and fluxing agents and sometimes filler metals are able to join these materials but the characteristics of these processes and the materials to be joined are at odds with one another. Still, users have become accustomed to the problems associated with fusion welding to the point that the problems are considered "normal." Ultrasonic welding of nonferrous metals in electrical connections has been demonstrated to eliminate most, if not all, of these problems. In fact, ultrasonic welding of metals is rapidly becoming the process of choice by informed design and manufacturing engineers. We will explore joining nonferrous metal with ultrasonic energy. Actual applications and operating cost comparisons will illustrate the degree of acceptance and the inherent advantages of ultrasonic metal welding for wiring and interconnection applications.
