Ultrasonic Metal Welding Machine for Terminal/Thimble Welding

At Dhruv’s Ultrasonics, we specialize in Ultrasonic Terminal 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 Terminal 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.

 

What is Ultrasonic Terminal Welding?

Ultrasonic terminal welding is a “cold welding” process. High-frequency mechanical vibrations remove oxide layers and create a solid-state metallurgical bond between the wire strands and the metal terminal plate.

Unlike soldering (which adds resistance and requires flux) or crimping (which can loosen over time), ultrasonic welding creates a fused joint that is electrically superior and mechanically stronger than the wire itself.

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Key Features & Advantages

1. Superior Electrical Conductivity

Achieve near-zero contact resistance. By fusing the metals at the molecular level, our machines prevent the voltage drops and heat buildup common in crimped connections—essential for EV and High-Voltage systems.

2. Multi-Material Capability

Easily weld dissimilar metals. Our technology excels at bonding Copper Wire to Copper Terminals or Aluminum Wire to Copper Terminals without the galvanic corrosion issues typical of other methods.

3. Precision Process Control

Powered by Lingke’s advanced digital generator, you get:

• Modes: Weld by Time, Energy, Height, or Collapse Distance.

• Quality Monitoring: Automatic alarms for “False Welds” or “Over Welds.”

• Data Logging: Traceability for every single joint produced.

4. Cost & Eco-Efficiency

• No Consumables: No solder, flux, crimps, or shielding gas needed.

• Low Energy: Uses a fraction of the power compared to resistance welding.

• Speed: Cycle times generally under 0.5 seconds.

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Applications

Our Ultrasonic Terminal Welding machines are the industry standard for:

• Automotive Wire Harnesses: Battery cable termination, Grounding lugs.

• New Energy / EV: High-voltage connectors, Charging gun terminals.

• Electronics: IGBT power modules, Capacitor tab welding.

• Switchgear: Solenoid and relay termination.

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Technical Specifications

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.