Ultrasonically Weld Non-ferrous and Dissimilar Metals

Sonobond Ultrasonics' SonoWeld® and SpliceRite™ ultrasonic metal welders weld without heat, current or consumables. They create solid-state metallurgical bonds quickly, efficiently and cleanly with repeatable accuracy. Long-lasting, quick-change steel taper lock tips perform up to 100,000 durable, dependable welds.

Quick Links:

• Click here to view our metal welding demo.
• Overview, features and specifications of our SonoWeld® 1600 - The SonoWeld® 1600 microprocessor-controlled welder performs spot welding of sheet to sheet and wire-to-terminal welds, including copper alloys, aluminum and tin-coated wires. Its system stores and recalls up to 250 weld protocols, and features automatic recall and setup of weld parameters by time, total energy or final weld thickness.
• The SonoWeld® 1600 is also the choice of battery manufacturers who require a fast, reliable method for spot welding multiple layers and/or delicate foils. It spot welds dissimilar metals to tabs or terminals, accommodating copper, aluminum, nickel and other non-ferrous metals. The ultrasonic bond has greater weld strength and electrical conductivity than bonds created by conductive adhesives. More information…

• Download our SonoWeld® Data Sheet
• Overview, features and specifications of our SpliceRight™ - The SpliceRite™ Wire Splicer is ideal for fast, efficient wire harness assembly and wire-to-wire splices without arcs, sparks, fumes, or melting wires. It consumes little energy and even accommodates tinned or heavily oxidized wires.
• Download the SpliceRite™ data sheet

In addition to its metal welders, Sonobond Ultrasonics produces custom-engineered ultrasonic bonders for a variety of other assembly applications.

• Sonobond's Ultrasonic Photovoltaic (PV) Modular System - The world's leading manufacturers of photovoltaic panels use Sonobond's Ultrasonic Photovoltaic (PV) Modular System for welding aluminum interconnects between photovoltaic cells. The ultrasonic welding process is neat, clean and economical, requiring no heat, fluxes, fillers, tapes or other consumables. It creates an ultra-reliable solid-state metallurgical bond without cracking the glass panels in photovoltaic cells.
• Filter Assembly Applications - Sonobond also has ultrasonic bonders that are ideal for filter assembly applications. Since they use no consumables, such as glue, thread or needles, they eliminate glue gaps and perforations, ensuring filter-trapping abilities.
• The RingMaster™ and Filter Collar Bonder™ - attach rigid plastic collars to nonwoven filter media.
• The SureWeld™ 20 Ultrasonic PlungeBonder™ - seals filter bag ends.
• Click here to view our filter assembly demo…
• Body Armor Applications - Nearly every major ballistic vest and body armor manufacturer in the United States uses Sonobond's ultrasonic textile bonders to ensure compliance with the current National Institute of Justice (NIJ) submersion tests.
• The SeamMaster™ High Profile Ultrasonic Bonder - cuts and seals in just one pass, eliminating stitch holes and glue gaps to seal the outer shell of the body armor and protect the ballistic-resistant material on the inside. Per NIJ 0101.06, wet conditioning standards now require protection from submersion for 30 minutes rather than protection from a spray shower.
• The SureWeld™ 20 attaches Velcro® to the outer shell of the vest.
• Medical Disposables Applications - Sonobond's SeamMaster™ ultrasonic sewing machines - provide secure barrier protection, satisfying tough regulatory requirements and protecting medical personnel from potentially hazardous fluids. As easy to use as conventional sewing machines, yet up to four times faster, Sonobond's machines require minimal training.

About Sonobond Ultrasonics:

Sonobond Ultrasonics is a worldwide leader in the application of ultrasonic welding and bonding technology. In 1960, Sonobond, then known as Aeroprojects, received the first patent ever awarded for ultrasonic metal welding. During the intervening 48 years, Sonobond has earned an outstanding reputation for its pioneering work and quality-engineered products. Today, Sonobond manufactures a complete line of ultrasonic welding and bonding equipment for customers in the automotive, appliance, electrical, HVAC, aerospace, filtration, medical, body armor and apparel industries.

Use the links below for:

• Product Information
• Ultrasonic FAQs

Depending on cleanliness requirements, Proceco systems incorporate any one or a combination of power spray, power flush, rotation with immersion, ultrasonics and precision aimed solid stream nozzles. A variety of full-flow multi-stage filtration systems ensure cleaning solutions do not exceed allowed particle sizes.

Proceco's engineering philosophy is simple - design and build robust, reliable cleaning systems that deliver the lowest cost per part. Proceco manufactures a wide range of industrial parts washers and cleaning systems incorporating advanced features that deliver high throughput with absolute process stability.

A complete selection of system configurations and options is available to meet your process or space requirement, and to handle a wide range of capacities for washing, rinsing and drying virtually any size workpiece, from precision machine parts in baskets to complex, heavy-duty individual components.

American GFM offers a complete line of ultrasonic cutting machines. Both three and six axis models are available to cut a large variety of materials. The machines are ideally suited for ultrasonic cutting carbon fiber, glass fiber, Kevlar, Prepreg and Honeycomb materials. Our ultrasonic cutting machines have the versatility to cut from multiple layers in excess of one inch thick to control depth ultrasonic cutting of a single layer. Because of superior design, AGFM ultrasonic cutting machines cut faster, more accurately and with better edge quality than any other machine available.

These machines are well suited for ultrasonic inlay cutting, ultrasonic scoring, ultrasonic core cutting or ultrasonic cutting of any type of material.

In addition, American GFM has developed a six axis ultrasonic cutting machines to facilitate contouring and beveling of complex shaped parts on honeycomb and other materials. All models use a standard American GFM Ultrasonic generator, converter, booster and horn with specially developed blades. The ultrasonic cutting blade cycles at 20,000 or 30,000 strokes per second. The model US50 permits quick automated tool changing and tool setting from standard vertical blades to disc cutters.

Activated vacuum work tables are nonmetallic but hard enough to enable the sharp edge of the blade to cut effectively. Numerous options are available to enhance productivity. Our expertise is building ultrasonic cutting machines, ultrasonic inlay cutting machines, ultrasonic core cutting machines.

The Standard 50 is the latest product from Rinco Ultrasonics in the 70kHz frequency range. Just as with the larger 20kHz and 35kHz machines from the Standard Series, the new machine is controlled by the ADG generator (Advanced Digital Generator). This enables user-friendly menu navigation and optimum frequency control. Constant power output is thus guaranteed.

The small bench appliance sets new standards particularly in terms of precision. Besides the time and energy modes, the integrated travel measurement also makes it possible to carry out welding operations in travel mode. The special low speed cylinder with improved smooth running guarantees operation without jerking and therefore an ultimate build up of force with applications in the micro domain.

The Standard 50 is suitable for all types of small welding applications. These can be found in the medical and electrical engineering fields, for example, where the printed circuit boards are fastened by means of riveted joints. The 70kHz appliance is also used for the manufacture of sensors or for welding mono and multi filaments. As with all Rinco products, the Standard 50 also has a modular design and can therefore be integrated in special purpose machines and production systems without problem.

When combined with an abrasive slurry, ultrasonic machining allows the tool to create accurate cavities of virtually any shape in hard, brittle materials.

This machining process is nonthermal, nonchemical, and nonelectrical. It does not change the metallurgical, chemical or physical properties of the workpiece.

The cutting vibration which Bullen uses in the ultrasonic machining process begins with converting a high-frequency electrical signal into an oscillatory mechanical motion. This motion is acoustically transmitted through a metal tool holder and cutting tool assembly. This linear oscillation is typically at a rate of 20,000 times per second, and, when used with an abrasive slurry flowing around the cutting tool, microscopic grinding occurs.

The machined area becomes counterpart of the cutting tool used. Using this technology, Bullen can offer you an almost limitless assortment of types and shapes of cuts to meet any design requirements you may have.

American GFM Corporation's Ultrasonic cutting machines shape problematic materials such as prepreg, cork, unvulcanized rubber, leather and honeycomb etc. with greater speed, accuracy and better edge quality than any other machines currently available. Precise cutting depth control is a GFM patent.

Contact American GFM Corporation today for your custom Ultrasonic cutting machine needs.