Ultrasonic Metal Welders

Techspan supply a range of equipment for ultrasonically welding of ‘non-ferrous’ or ‘white’ metals – equipment for wire splicing, terminal welding, spot welding, continuous foil welding and more.  Techspan supply Sonobond Ultrasonic metal welding systems – the first patent ever issued for ultrasonic metal welding was awarded to Sonobond Ultrasonics (then known as Aero-projects) back in 1960. Sonobond Ultrasonics has been the worldwide leader in the development of ultrasonic metal welding equipment.

Sonobond ultrasonic metal welders create precise, solid-state metallurgical welds without heat, current, or consumables. This is achieved by introducing high-frequency vibration while the weld-ment is under a moderately high clamp force. non-ferrous similar and dissimilar metals can be welded with repeated accuracy.

Documents

Brochure Metal Welding
Wire Splicer
Weld Master MH1545
Tube Terminator
Spot Welder 1600
Foil Splicer

Spot Welder model SonoWeld 1600

Ultrasonic Metal Welder model SonoWeld 1600 –

  • Performs spot welds, as well as wire-to-terminal welding
  • Welds multiple layers and/or delicate foils to tabs or terminals for lithium-ion and NiMH battery assembly
  • Joins up to 10 stranded wires from flat flexible circuit to multi-connection terminals in a single pulse
  • Microprocessor-controlled system allows storage and recall of over 250 weld protocols
  • Digital display allows selection of welding modes by time, energy or distance, with automatic frequency control and overload protection
  • Outputs 1,500 or 2,500 watts of power to weld non-ferrous similar or dissimilar metal assemblies, including copper to aluminum

Single Point Grounded Welder model SPG 2600

Ultrasonic Metal Welder model SPG 2600 – single point ground welder –

Microprocessor-controlled metal spot welding system for producing the single point ground terminals used in complex automotive electronic components and circuitry. Ultrasonically welds up to 18 wires to a single terminal with one pulse before automatically folding the terminal arms to provide stress relief on the joint.

Sonobond’s Single Point Ground Welder SPG 2600 ultrasonically welds wire bundles of up to 20 square millimeters to a single terminal. This easy-to-use, microprocessor-controlled unit accomplishes the weld in one pulse. The SPG 2600 is designed specifically for producing the single point ground terminals used in eliminating the electrical noise caused by the large number of complex electronic components in automotive circuits. Once the weld has been made, the unit automatically crimps the terminal arms around the wires to provide stress relief on the joint.

The Single Point Ground Welder utilizes the patented Wedge-Reed system. This creates precise, ultra-reliable, solid-state metallurgical bonds without heat, current, fluxes, or fillers. Even lightly tinned or oxidized wires can be accommodated by the unit.

Handles Bundles of Up to 20 Square Millimeters

Sonobond’s Single Point Ground Welder outputs 2,500 watts of power and can confidently handle up to 18 wires. The power supply features a built-in microprocessor that stores and recalls up to 250 weld protocols and permits weld parameters to be selected by time or energy. The unit’s heat-treated, tool steel Taper Lock Tips perform up to 100,000 welds and can be easily removed and replaced.

SpliceRite Wire Splicer

Ultrasonic Metal Welder model SpliceRite –

  • Creates a true solid state metallurgical bond with the lowest possible voltage drop, and minimal energy consumption
  • Produces no arcs, sparks or fumes, and does not melt the wires
  • Microprocessor controller welds by height, energy or time, and can recall up to 250 weld protocols
  • Bonds wire bundles even if the wires are oxidized
  • 1500 and 2500 watt power supplies are available

Documents

Brochure SpliceRite Wire Splicer 

Dual Head Spot Welder

Ultrasonic Metal Welder model Dual Head – spot welder –

  • Features two ultrasonic welding heads, one on either side of the welding area, for increased welding capacity
  • Welds non-ferrous sheet metal, including aluminum up to 3mm thick, and reduces tip sticking on thinner aluminum as used for automotive applications
  • Welds up to 80 layers of foil to tabs and terminals, as used for advanced battery and super capacitor applications
  • Attaches wires to terminals
  • Accommodates lightly tinned or oxidized wires
  • Creates a solid-state metallurgical bond with high conductivity and without producing arcs, sparks or fumes, or melting at the weldment
  • Microprocessor controller welds by height, energy or time, and can recall up to 250 weld protocols
  • 3,500 watt power supply

Documents

Brochure Dual Head Spot Welder

Dual Head SpliceRite Wire Splicer

Ultrasonic Metal Welder model Dual Head SpliceRite –

  • Features two ultrasonic welding heads, one on either side of the welding area, for increased welding capacity
  • Welds wire bundles with cross-sectional areas of up to 100 sq. mm.—in a single pulse. It’s suitable for heavy-duty cables used in cars, trucks and industrial machinery
  • Accommodates lightly tinned or oxidized wires
  • Creates solid-state metallurgical bonds with high conductivity and without producing arcs, sparks or fumes, or melting at the weldment
  • Microprocessor controller welds by height, energy or time, and can recall up to 250 weld protocols
  • 3,500 watt power supply

Documents

Brochure Dual Head SpliceRite

WeldMaster C-Frame I

Ultrasonic Metal Welder model WeldMaster C-Frame I –

  • Effectively accommodates large metal parts, such as those used in the automotive industry
  • Outputs 2500 watts of power to weld nonferrous and dissimilar metal assemblies, including copper to aluminum
  • Virtually eliminates the problem of tips sticking to aluminum parts
  • C-Frame I has a 14-inch throat depth and a single head which usually completes the weld operation in less than 1.5 seconds

Documents

Brochure WeldMaster C-Frame I

WeldMaster C-Frame II

Ultrasonic Metal Welder model WeldMaster C-Frame II –

  • Effectively accommodates large metal parts, such as those used in the automotive industry
  • Outputs 2500 watts of power to weld nonferrous and dissimilar metal assemblies, including copper to aluminum
  • Virtually eliminates the problem of tips sticking to aluminum parts
  • C-Frame II has an 18-inch throat depth and is available with a single head or double-head, which further deduces weld time and energy

Documents

Brochure WeldMaster C-Frame II

Tube Terminator

Ultrasonic Metal Welder model Tube Terminator –

  • Hand-guided one-step crimp/seal copper and aluminum tube welder
  • Seals refrigerator/air conditioner tubing — even when charged
  • Produces quick, airtight bonds without brazing

Documents

Brochure Tube Terminator

Foil Splicer MS5010B

Ultrasonic Metal Welder model Foil Splicer MS-5010B –

  • Continuous seam welding and splicing units used in virtually all U.S. foil mills
  • For thin aluminum and copper foils up to 0.004″(0.1mm) thick and up to 48″ wide
  • Seams and splices are produced faster and cleaner than by any other method
  • Welds aluminum interconnects between photovoltaic cells

Documents

Brochure Foil Splicer model MS 5010B

Photovoltaic (PV) Modular System

Ultrasonic Metal Welder model Photovoltaic (PV) Modular System –

  • Weld aluminum strips to metallized glass on PV modules
  • The resulting interconnects between the PV cells create an array with excellent conductivity
  • The high frequency (50kHz) low amplitude system precludes cracking of the glass panels
  • No melting, excessive heat, fluxes, filler metals, tapes or other consumables
  • Requires minimal training and is easy to operate and to integrate into PV handling systems
  • Power supply with automatic frequency control and welding head with a rotatable disk tip are suitable for integration into production line systems for PV cell manufacturing

Documents

Brochure PhotoVoltaic Modular System