Why Ultrasonic Welding

Ultrasonic welding of metal foils has been utilized in industry since then 1960’s.  The low temperature nature of an ultrasonic bond allows clean and energy-efficient welding of metal foils at an affordable cost.  Benefits include:

  • Unique bonding mechanism allows welding similar and dissimilar metal combinations
  • Room temperature bond has low energy consumption and creates almost no heat around sensitive materials such as electronics
  • Since no melting occurs the process requires no special atmosphere
  • By eliminating fasteners, thermal and electrical conductivity of the joint achieve that of billet
  • Modern ultrasonic welding controls allow for in process quality monitoring and SPC data retention

See It in Action

The SonicLayer® Seam can be configured in a wide variety of orientations and customized equipment needs. The base welding unit has been integrated to stationary weld stations, custom high volume automation, as well as becoming the end effector for a large industrial robot. Contact us to discuss your specific needs.

How it Works

Ultrasonic welding works by using sound to rapidly vibrate the device while pushing on the surface of the metal.  This scrubbing motion removes the metal oxide layer while the downward pressure pushes the surfaces together.  The result is a low temperature solid state bond. 

Bonding happens so fast that the metal doesn’t even heat up!!

Fabrisonic’s patented SonicLayer® X̅ Seam Welder technology is based on our 3D printing technology. In addition to the downward force and the side-to-side force, the textured sonotrode is also rotating.

Applications

Current ultrasonic seam welders are primarily limited on both power and down force.  These restrictions impose limits on:

  • The speed of production
  • The thickness of material coupling
  • The type of metal foil that can be welded.

Fabrisonic’s SonicLayer® X̅ Seam Welder has been engineered from the ground up with a focus on maximum power and clamping force.  Fabrisonic’s patented design allows a leap in ultrasonic welding capabilities.

The SonicLayer Seam can easily join:

  • Multiple layers of aerospace grade aluminums
  • High strength copper including beryllium copper foils
  • Refractory metals such as tantalum and molybdenum
Example Electrical shunt
Example Electrical shunt
bimetallic
Target
6061Al-110Cu-50X
It can join aluminum to copper while embedding ceramics.
It can join aluminum to copper while embedding ceramics.
It can join aluminum with metal matrix composites for optimizing strength and weight.
It can join aluminum with metal matrix composites for optimizing strength and weight.
It can join radiation shielding tantalum to steel.
It can join radiation shielding tantalum to steel.
Example Electrical shunt
bimetallic
Target
6061Al-110Cu-50X
It can join aluminum to copper while embedding ceramics.
It can join aluminum with metal matrix composites for optimizing strength and weight.
It can join radiation shielding tantalum to steel.