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Ultrasonic metal welding machines are mainly used for soft non-ferrous metals and their alloys including copper, aluminum, nickel, silver and gold. They are suitable for solid-state cold bonding of thin sheets, foils, fine wires and precision parts, and can weld both similar and dissimilar metals (e.g. copper and aluminum).

I. Highly Recommended Materials (Weldability: ★★★★★)

• Copper / Oxygen-free copper: Tabs for power batteries, busbars, wire harness terminals, copper layers on IBT substrates.

• Pure aluminum / Series 1 aluminum: Battery aluminum foils, busbars, heat sinks, air conditioner aluminum tubes.

• Nickel / Nickel strips: Battery tabs, sensor pins, battery connecting strips.

• Silver / Gold: Relay contacts, semiconductor leads, precision electronic components.

• Brass / Phosphor bronze: Connector terminals, switch contacts (Parameters shall be properly adjusted to prevent zinc volatilization).

II. Weldable Materials (Parameter Optimization Required) (Weldability: ★★★☆☆)

• Aluminum alloys (Series 3 / Series 5): Soft Al-Mg & Al-Mn alloys, applied to battery casings and lightweight parts.

• Magnesium alloys: Thin-walled parts and heat dissipation components. Control welding energy to avoid oxidation.

• Coated metals: Tin-plated / Nickel-plated copper strips, aluminum-coated steel strips. Thin coatings are weldable, while thick and hard coatings are difficult to weld.

• Thin-gauge stainless steel: 0.1–0.3mm thin sheets, shielding cans, miniature housings. Special welding horns and high amplitude are required.

III. Typical Dissimilar Metal Combinations

• Copper ↔ Aluminum: Battery tabs & busbars, copper-aluminum transition bars (most mature application).

• Aluminum ↔ Nickel: Connection between battery tabs and protection boards.

• Copper ↔ Nickel: Terminals & nickel strips, electronic component pins.

• Aluminum ↔ Stainless steel: Encapsulation of thin aluminum sheets and stainless steel housings.

IV. Non-weldable Materials

• High-carbon steel, alloy steel, cast iron: High hardness and poor ductility, unable to form stable molecular bonds.

• High-silicon / High-copper aluminum alloys, thick titanium materials: High brittleness, prone to cracking.

• Hard coatings (Hard chrome, thick nickel plating): Block vibration transmission and easily cause cold solder joints.

V. Common Application Scenarios

• New energy batteries: Tabs (copper / aluminum foils), busbars, cell connecting strips, module copper bars.

• Automotive electronics: High-voltage wire harness terminals, sensor shields, connector pins.

• Precision electronics: Mobile phone shielding cans, wearable device brackets, relay contacts, LED copper-clad substrates.

• Refrigeration & home appliances: Sealing of air conditioner copper tubes, welding of cooling fins, internal wire harnesses for home appliances.

VI. Welding Forms & Thickness Specifications

• Forms: Foils (starting from 0.05mm), thin sheets, fine wires, braided wires, terminals and short strips.

• Thickness: Single copper/aluminum material ≤ 2mm; total thickness of dissimilar metals ≤ 3mm. Ultra-thin foils can be welded in multiple layers.

VII. Core Advantages

• Solid-state cold welding: Operating temperature far below metal melting point, no thermal damage, sparks or spatter.

• Molecular-level bonding: Weld joints feature high strength, low contact resistance and excellent electrical conductivity.

• No filler metal required: Eco-friendly and pollution-free, ideal for clean and sterile working environments.