Ultrasonic welding is the use of high-frequency vibration waves transmitted to the surfaces of two objects to be welded, and under pressure, the surfaces of the two objects rub against each other to form fusion between molecular layers. The main components of an ultrasonic welding system include an ultrasonic generator, transducer, amplitude rod, welding head triad, mold, and frame.

Ultrasonic welding is the process of converting 50/60 Hz current into 15, 20, 30, or 40 KHz electrical energy using an ultrasonic generator. The converted high-frequency electrical energy is converted back into mechanical motion of the same frequency through a transducer, and then the mechanical motion is transmitted to the welding head through a set of amplitude changing rod devices. The welding head transfers the received vibration energy to the joint of the workpiece to be welded, where the vibration about ultrasonic metal welding energy is converted into thermal energy through friction, melting the area of the component to be welded. Ultrasonic waves can not only be used for welding metals and hard thermoplastic plastics, but also for processing fabrics and films.

The principle of ultrasonic metal welding is a special method of connecting the same or different types of metals using mechanical vibration energy at ultrasonic frequencies (over 16KHz). During ultrasonic welding, the metal does not transmit current to the workpiece, nor does it apply a high-temperature heat source to the workpiece. Instead, under static pressure, the frame vibration energy is converted into frictional work, deformation energy, and limited temperature rise between the workpieces. The metallurgical bonding between joints is a solid-state welding achieved without melting the base material. Therefore, it effectively overcomes phenomena such as splashing and oxidation generated during resistance welding. Ultrasonic metal welding machine can perform single point welding, multi-point welding, and short strip welding on thin wires or sheets of non-ferrous metals such as copper, silver, aluminum, and nickel. It can be widely used for welding thyristor leads, fuse blades, electrical leads, lithium battery pole pieces, and pole ears.

Ultrasonic welding has a wide range of applications and long prospects. For all application markets, its unique advantages - fast, efficient, clean, and firm - have won recognition from various industries.