Ultrasonic Working Process

The ultrasonic metal welding process is characterized by its speed, cleanliness, and cost-effectiveness.
Although the ultrasonic welding process differs from cold welding and friction welding, it shares notable similarities with them in certain respects; this process generates high-density energy through high-frequency mechanical vibrations. The welding horn vibrates mechanically in a direction parallel to the surface of the workpieces, while simultaneously applying static pressure perpendicular to the welding interface. Concurrently, high-frequency shear forces are also applied in synchronization. When these shear forces exceed the material’s elastic limit, localized sliding begins to occur at the contact surfaces of the workpieces. During the welding process, the direction of the shear forces alternates continuously at a frequency of tens of thousands of times per second; this action serves to disrupt and remove surface contaminants—such as oil and grease—thereby enabling multi-point contact between the clean metal surfaces. As the high-frequency vibrations persist, the clean contact zones progressively expand until the entire welding area becomes completely clean. Simultaneously, atomic diffusion takes place across the contact surfaces, leading to the recrystallization of the metal and the formation of a fine-grained structure, thereby exhibiting the distinct microstructural characteristics typical of cold-deformed metals.