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Why Use an Ultrasonic Welder?

Number of visits: Date:2020-07-16

When it comes to your electrical connections only the best will do and the best splice comes from utilizing Ultrasonic welders. Long gone are the days of acid-solder. Today, the best way to create a superior electrical splice is to utilize an ultrasonic welder. 


How does it work?

An ultrasonic welder uses high frequency ultrasonic acoustic vibrations to create a solid state weld. This means that it literally fuses the wires into one unified piece. The ability to use an ultrasonic welder on tinned copper is a relatively new capability. So how do we do it? The process begins by separating the wires that are to be spliced. Careful attention must be made to ensure that the ends of the wires are properly stripped. Once this is completed, the machine is turned on and calibrated to the proper setting. With an ultrasonic welder, there is the ability to create a multitude of settings to handle any job regardless of wire gauge or conductor type. When all of the wires are ready and the machine has been prepped, the wires are clustered together in preparation for the splice. It is at this point in the process that semi rigid heat shrink is slid down over the wires. The wire conductors are staggered into the welding bay and are aligned with the welding tip. The machine is activated, the tip lowers, and the splice is formed used precisely tuned ultrasonic vibrations. Again, this fuses the metal wires into one solid piece. Once they have been welded, there is no going back. It’s that strong! Since we positioned the force directly over the splicing surface, we eliminated any bending stress on the new connection. After a thorough inspection of the wire, the semi rigid heat shrink that we added earlier is positioned over the new weld covering it completely. Now the heat shrink is activated in order to make a complete seal. This ensures maximum protection from moisture intrusion. It also reinforces the weld by moving any further potential bending stresses off of the point of the weld and out to the edges of the heat shrink, into the flexible wire. Once this is done, the new connection is inspected for quality assurance.


Formerly, many industries such as the automotive industry would use the acid-solder method. This method involved preparing the wires in a similar fashion to what is described above however, the wires would be held together using a terminal clip. This clip would basically work as a lock holding the wires together but not fusing them. Next, the wires would be dipped in acid to remove any oils or impurities. After removing the excess acid, the wires and terminal clip would be dipped in molten solder. This technique leaves a lot to be desired. For starters, you run the risk of introducing residual acid to the environment where you place your wires. Additionally, there is no extra layer of protection for your connection. Whereas the connection made using the ultrasonic welder is protected with semi-rigid heat shrink, the acid-solder method has nothing.



"Ultrasonic welds offer exceptional thermal and electrical conductivity"


Utilizing an ultrasonic welder saves not only time and money, but resources as well. It doesn’t require the terminal clips or acid and solder that other methods need. Additionally, the entire process is several steps shorter than most other methods. Still not convinced? Ultrasonic welds offer exceptional thermal and electrical conductivity and the potential to eliminate other more expensive mechanical connections in a system. This method is the superior way to create a durable, long-lasting, conductive electrical splice. 

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