Ultrasonic Metal Welding Machine
JSB Ultrasonic’s Ultrasonic Metal Welding Machines join wires, foils, battery tabs, and other conductive components without solder, flux, or adhesives — producing strong, low-resistance solid-state welds. Our range covers battery pack welding, copper-aluminium joining, and wire splice applications.
This is a purpose-built joining process for the demands of EV battery production, wire harness assembly, and electrical connector manufacturing, where a fast, consistent, solder-free metal joint is essential.
What is a Ultrasonic Metal Welding Machine?
An ultrasonic metal welding machine clamps overlapping metal foils, tabs, or wires between an anvil and a vibrating horn. High-frequency vibration creates micro-scale friction at the interface between the metal layers, breaking down surface oxides and creating a true metallurgical solid-state bond — without melting either material, unlike resistance or laser welding. This produces a low, consistent electrical resistance at the joint and can reliably weld multiple thin foil layers together.
Key Features
- Low, consistent electrical resistance at every joint
- Solid-state process avoids melting thin metal foils
- No solder, flux, or post-weld cleaning required
- Reliably welds multiple stacked foil layers at once
- Fast cycle times suited to high-volume production
- Suitable for dissimilar metal combinations (e.g. copper-to-aluminium)
Applications
Our ultrasonic metal welding machines range is used across:
- EV battery pack and module tab welding
- Copper-to-aluminium busbar welding
- Wire harness splicing and termination
- Electrical connector assembly
- Motor and coil winding termination
Technical Specifications
| Parameter | Specification |
|---|---|
| Machine Type | Ultrasonic Metal Welding Machine |
| Frequency | 15kHz / 20kHz |
| Power Output | 2000W – 4200W |
| Material Compatibility | Copper, Aluminium, Nickel, Battery Foils |
| Control System | Digital / PLC Based Control |
| Voltage | 220V / 380V |
| Warranty | 1 Year |
Why Choose JSB Ultrasonic?
JSB Ultrasonic supplies ultrasonic metal welding systems to battery, electronics, and electrical component manufacturers who need fast, consistent, low-resistance joints. We size frequency, power, and anvil/horn design to your specific foil, wire, or busbar configuration.
Frequently Asked Questions
What metals can this machine weld?
It is designed for copper, aluminium, and nickel-plated foils and tabs, including dissimilar metal combinations like copper-to-aluminium.
Can it weld multiple thin foil layers at once?
Yes, ultrasonic metal welding can reliably join multiple stacked foil layers to a single busbar or terminal in one weld.
Is this suitable for EV battery production?
Yes, ultrasonic metal welding is widely used for battery tab and busbar joining in EV module and pack assembly.
Do you provide installation and training?
Yes, installation support and operator training are included so you can get the machine running correctly from day one.
Do you offer customization?
Yes, our engineers can review your part or application and recommend a customized fixture, horn, or configuration.
What after-sales support is available?
We provide spare parts, preventive maintenance guidance, and remote or on-site troubleshooting support for the life of the machine.
Buy Ultrasonic Metal Welding Machine in India
We supply ultrasonic metal welding machines to manufacturers in Delhi, Noida, Gurgaon, Faridabad, Bengaluru, Chennai, Sonipat, and across India, with export support internationally. Contact JSB Ultrasonic for a machine recommendation and quote tailored to your application.
