Ultrasonic Metal Welding Machine
At Dhruv’s Ultrasonics, we specialize in ultrasonic metal welding machine designed for precision bonding of non-ferrous metals like copper, aluminum, and their alloys. Our machines are engineered for industries that demand clean, high-strength, and high-conductivity welds — such as EV battery manufacturing, solar panel assembly, wire harness production, and electrical component fabrication.
Unlike traditional welding, ultrasonic metal welding uses high-frequency mechanical vibrations and pressure to create a solid-state weld — without melting the materials, eliminating oxidation, thermal distortion, and the need for solder, flux, or filler materials.
Models Offered by Dhruv’s Ultrasonics
We offer a complete range of ultrasonic metal welding machines in 20 kHz frequency, with power capacities tailored to suit different applications and production volumes.
| Parameter | Specification |
|---|---|
| Frequency | 20 Khz |
| Power | 3000 Watt |
| Input Voltage | AC 220 Volt |
| Weld Area Capacity | Up to 20 mm² |
| Amplitude Adjustment | 10% to 100% |
| Welding Modes | Time, Energy |
| Control Interface | Digital Touchscreen |
| Cooling System | Air |
| Horn Material | Titanium |
| Parameter | Specification |
|---|---|
| Frequency | 20 KHz |
| Power | 5000 Watt |
| Input Voltage | AC 220 Volt |
| Weld Area Capacity | Up to 35 mm² |
| Amplitude Adjustment | 10% to 100% |
| Welding Modes | Time, Energy |
| Control Interface | Digital Touchscreen |
| Cooling System | Air |
| Horn Material | Titanium |
| Parameter | Specification |
|---|---|
| Frequency | 20 KHz |
| Power | 7000 Watt |
| Input Voltage | AC 220 Volt |
| Weld Area Capacity | Up to 50 mm² |
| Amplitude Adjustment | 10% to 100% |
| Welding Modes | Time, Energy |
| Control Interface | Digital Touchscreen |
| Cooling System | Air |
| Horn Material | Titanium |
Applications of Ultrasonic Metal Welding Machine
Ultrasonic metal welding is used extensively in sectors where electrical conductivity, strength, and clean bonding are crucial. Dhruv’s Ultrasonics offers machines built for continuous use and automation integration, ideal for modern production lines.
Electric Vehicle (EV) Battery Manufacturing
- Tab-to-tab welding of aluminum and copper cells
- Welding cell terminals to busbars in battery modules
- Ensures strong, conductive joints without melting materials
- Maintains the integrity of sensitive battery components
- Enables high-throughput welding in automated lines
- Reduces heat-affected zones and prevents oxidation
Solar Panel and Energy Storage Assembly
- Welding of aluminum and copper foil interconnects
- Tab-to-tab welding in solar battery modules
- Suitable for thin metal layers used in PV cells
- Minimizes thermal impact on active cell materials
- Enhances reliability of outdoor solar installations
- Delivers strong, corrosion-resistant connections
Wire Harness and Cable Welding
- Reliable joining of stranded and solid wire bundles
- Terminal-free bonding for lightweight design needs
- Avoids overheating or damaging insulation materials
- Reduces contact resistance in automotive connectors
- Ideal for fusing copper and aluminum conductors
- Used in EVs, white goods, control panels, and sensors
PCB and Electronics Assembly
- Precision bonding of terminals and contact pads
- Ideal for fine wire bonding on circuit boards
- Eliminates the need for soldering or flux
- Maintains electrical performance without heating parts
- Used in power banks, chargers, sensors, and micro devices
- Reduces component stress in tight board layouts
Industrial Automation and Power Systems
- Welding of copper busbars and laminated foils
- Reliable joining of thick conductor cables and tabs
- Ideal for energy meters, capacitors, and heavy-duty panels
- Used in switchgear, transformers, and smart grids
- Reduces production downtime with fast cycle times
- Ensures stable, low-resistance electrical pathways
Technical Specifications of Ultrasonic Metal Welding Machine
| Parameter | 3000W Model | 5000W Model | 7000W Model |
|---|---|---|---|
| Frequency | 20 kHz | 20 kHz | 20 kHz |
| Power Output | 3000 W | 5000 W | 7000 W |
| Input Voltage | 220V AC | 220V AC | 380V AC |
| Weld Area Capacity | Up to 20 mm² | Up to 35 mm² | Up to 48 mm² |
| Amplitude Adjustment | 10% to 100% | 10% to 100% | 10% to 100% |
| Weld Modes | Time, Energy | Time, Energy | Time, Energy |
| Control Interface | Digital Touchscreen | Digital Touchscreen | Digital Touchscreen |
| Cooling System | Air | Air | Air |
| Automation Compatibility | Yes | Yes | Yes |
| Horn Material | Titanium | Titanium | Titanium |
Frequently Asked Questions (FAQ)
What is ultrasonic metal welding machine?
Ultrasonic metal welding is a solid-state process where high-frequency vibrations and moderate pressure are used to bond metals. It does not involve melting, making it ideal for sensitive electronic or power components.
Which metals can be welded?
Primarily used for copper, aluminum, nickel, silver, gold, and lithium materials. It is not suitable for steel or high-resistance alloys.
Is it suitable for EV battery production?
Yes. It is widely used for welding cell tabs, busbars, and conductors in lithium-ion and LFP battery modules.
Does the process damage wires or foils?
No. Because ultrasonic welding does not use heat or flame, it preserves the electrical and mechanical properties of wires and foil stacks.
Can these machines be automated?
Yes. All our models support PLC integration and can be added to robotic or semi-automatic lines.
Do you provide installation and training?
Yes. We offer on-site installation, application testing, and complete training for operators and maintenance staff.
Why Choose Dhruv’s Ultrasonics Ultrasonic Metal Welding Machne
- Decades of experience in ultrasonic welding technology
- Industry-specific solutions for EV, solar, and electronics sectors
- In-house support for application development and horn design
- Pan-India service, fast response, and spare part availability
- Fully tested machines with customer sample validation
- Ready for Industry 4.0 automation integration