Products from Sonobond related to Metal Welding.

The first patent ever issued for ultrasonic metal welding was awarded to Sonobond Ultrasonics (then known as Aeroprojects) in 1960. Since then, the company has been the worldwide leader in the development of ultrasonic metal welding equipment.
Sonobond ultrasonic metal welders create precise, solid-state metallurgical bonds without heat, current, or consumables. This is accomplished by introducing high-frequency vibration while the weldment is under moderately high clamping force. In this way, non-ferrous similar and dissimilar metals can be welded with repeated accuracy.

SonoWeld® 1600
Ultrasonic Metal Spot Welder

Ultrasonic Single Point Ground Welder SPG 2600

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
Ultrasonic Single Point Ground Welder SPG 2600:

  • Single point ground terminals used in complex automotive electronic components and circuitry
  • Ultrasonically welds up to 18 wires to a singleterminal with one pulse
  • Automatically folds the terminal arms to provide stress relief on the joint
  • Ultrasonically welds wire bundles of up to 20 square millimeters to a single terminal
  • Easy to-use, microprocessor-controlled unit accomplishes the weld in one pulse
  • 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
  • Utilizes the patented Wedge-Reed system
    • 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
  • Outputs 2,500 watts of power
    • Confidently handle up to 18 wires
  • 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
  • Heat-treated, tool steel Taper Lock Tips perform up to 100,000 welds and can be easily removed and replaced.
  • Requires only minimal training

SpliceRite™ Ultrasonic Wire Splicer

Dual Head Ultrasonic Metal Spot Welder

SpliceRite™ Ultrasonic Wire Splicer​:

  • 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
Dual Head Ultrasonic Metal 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
  • Uses Sonobond's 3,500 watt power supply

Dual Head SpliceRite™ Ultrasonic Wire Splicer

WeldMaster™ C-Frame I & II Ultrasonic Metal Spot Welders

Dual Head SpliceRite™ Ultrasonic Wire Splicer:
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  • 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
  • Uses Sonobond's 3,500 watt power supply
WeldMaster™ C-Frame I & II Ultrasonic Metal Spot Welders:

  • ​​​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
  • C-Frame II has an 18-inch throat depth and is available with a single or a double head, which further reduces weld time and energy

Tube Terminator™ Ultrasonic Copper & Aluminum Tube Welding

Foil Splicer™ Ultrasonic Foil Splicing

Tube Terminator™ Ultrasonic Copper & Aluminum Tube Welding:
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  • 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
Foil Splicer™ Ultrasonic Foil Splicing:

  • 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

Photovoltaic (PV) Ultrasonic Modular System

Photovoltaic (PV) Ultrasonic Modular System:
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  • 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
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