Sonobond's Free, No-Obligation Ultrasonic Metal Welding Viability Test Helps Companies Find Practical, Cost-Effective Solutions for Their Specific Manufacturing Requirements

Sample ultrasonic welds are made using materials supplied by prospective customers. Sonobond then recommends the ultrasonic metal welder that is best suited to each company's particular application.

WEST CHESTER, PA - Janet Devine, President of Sonobond Ultrasonics, announced today that the company's free Ultrasonic Metal Welding Viability Test is proving to be an important help to firms across a wide spectrum of industries. She explains, "Although more and more manufacturers recognize the advantages of ultrasonic metal welding, they still need to confirm that the process is right for their specific situation. Our no-charge, no-obligation viability test lets companies do this by sending us their similar or dissimilar non-ferrous metals so we can make sample welds on our machines. At the same time, it gives our technical team the opportunity to recommend the Sonobond ultrasonic welding equipment best suited for that company's requirements."

Ms. Devine goes on to say, "Our ultrasonic metal welders are utilized in an increasingly wide variety of applications. For example, our machines weld stranded wire-to-wire and wire-to-terminals for electrical wire harnesses and bus bars. They play an important role in welding the terminals of lithium-ion batteries, foil-wound capacitors, thin aluminum or copper foil, and electrical contacts. Our equipment is important to the manufacture of fuses/circuit breakers, ignition modules, starter motors, and photovoltaic panels. Sonobond ultrasonic metal welders are also used to close HVAC tubing, replacing crimp and solder methods. In addition, they can spot weld large metal parts for automotive assembly."

Ultrasonic Welding Offers important Advantages

Ultrasonic metal welding is a reliable, well-established, environmentally-friendly process that produces solid-state metallurgical bonds without excessive heat, current, or consumables. This is accomplished by introducing high-frequency vibration while the weldment is under moderately high clamping force. Non-ferrous similar and dissimilar metals can be welded with repeated accuracy in a single operation that takes only seconds. Sonobond ultrasonic metal welders feature quick-change taper lock tips that are capable of performing up to 100,000 welds before replacement.

All of Sonobond's ultrasonic metal spot welders are made in the U.S.A. They have an important advantage over other types of metal welding equipment because they use the unique, patented "Wedge-Reed" bonding system. This maximizes welding effectiveness by combining high vibratory force with low amplitude coupling. Dependability is assured by utilizing shear mode vibration parallel to the welding surface. At the same time, bending stress is eliminated by positioning the line of force directly over the welding surface. This is the only ultrasonic system able to reliably weld most oxidized and tinned metals in one pulse, without pre-cleaning.

Arranging for an Ultrasonic Metal Welding Viability Test

According to President Devine, it is very easy for companies to arrange to have Sonobond make sample welds. She says, "They can visit our website at and click the button requesting the Ultrasonic Welding Viability Test. There is a short form asking some basic information that can be completed quickly and easily. As soon as we receive a request, we respond promptly. Of course, firms are welcome to call us if that is more convenient.

"We're often able to determine upfront whether an application seems feasible. If we believe it is, we let the company know the amount of materials required to prepare their sample welds. We also discuss details of their application with them, including the geometry and specifications of the finished weld. Typically, we can meet or come very close to these requirements with our lab tooling. If-as occasionally happens-custom tooling is needed in order to make the sample weld, we may charge to cover that expense. Of course, we will discuss any such costs with the company beforehand. But usually there is no charge. Once everything is in place, the test itself can normally be completed within a week or so."

Expert Custom Tooling

Performing the Ultrasonic Metal Welding Viability Test gives Sonobond's technical staff the opportunity to discuss what tooling customization may be needed to satisfy a company's specific production welding requirements.

Sonobond has over 50 years of ultrasonic metal welding experience and is very adept at meeting each customer's unique part specifications. This includes designing the tooling to assure the various pieces are held together in their proper orientation while the weld is being completed. Sonobond's technicians also make certain the weld conforms to the customer's dimensional tolerances, electrical requirements, and mechanical specifications.

Sonobond Leadership in Ultrasonic Welding

Sonobond offers an impressive selection of ultrasonic metal welding equipment. Here are a few examples:

· The SonoWeld® 1600 Digital Metal Spot Welder is ideal for spot and wire-to-terminal welding. It is frequently used to weld multiple layers and/or delicate foils to tabs or terminals for lithium and NiMH battery assembly. It confidently welds dissimilar metals, such as copper to aluminum, and allows storage and recall of over 250 weld protocols.

· The SpliceRite(TM) Wire Splicer creates solid-state metallurgical welds of wire bundles up to 60 sq. mm in size. This equipment can splice tinned or oxidized wires up to 35 sq. mm in just one pulse.

· The SPG 2600 Single Point Ground Welder produces single point ground terminals for complex automotive electronic circuitry. It welds up to 18 wires to one terminal and automatically folds the terminal arms to provide stress relief on the joint.

· The Dual Head SpliceRite(TM) Wire Splicer features two ultrasonic welding heads, one on each side of the welding area. This enables it to handle wire bundles from 48 to 100 sq. mm in a single pulse. It is especially suitable for splicing the heavy-duty cables used in cars, trucks, and industrial machinery. Even lightly tinned or oxidized wires up to 60 sq. mm can be accommodated.

· The Dual Head Spot Welder also features two ultrasonic heads. It welds non-ferrous sheet metal, including aluminum up to 3 mm thick, while reducing tip sticking. This makes it ideal for automotive applications. The Dual Head Spot Welder is also used for advanced battery and capacitor applications because it can weld up to 80 layers of foil to tabs and terminals.

In addition to the machines described above, Sonobond offers these other ultrasonic metal welders: the Tube Terminator(TM), Weldmaster(TM) C-Frame, Photovoltaic (PV) System, Foil Splicer(TM), and Weldmaster(TM) MH-1545 Spot Welder.

President Devine summarizes what Sonobond has to offer by saying, "We have ultrasonic metal welders for a broad range of applications. And they can be customized to match the requirements of individual manufacturers. But adding one of our machines does represent a capital investment for most companies. So we encourage them to find out what we have to offer and then to take advantage of our Ultrasonic Metal Welding Viability Test. In this way, we can prove to their satisfaction that our equipment will provide the dependable, cost-effective solutions they need and want."

Decades of Innovation and Leadership

Sonobond is recognized worldwide for its application of ultrasonic welding and bonding technology. In 1960, the company-then known as Aeroprojects-received the first patent ever awarded for ultrasonic metal welding. In the 52 years since then, Sonobond has earned and maintained a well-deserved reputation for its pioneering work and quality-engineered products. Today the company manufactures a complete line of ultrasonic welding and bonding equipment. Among its many customers are leading firms in the electrical, automotive, appliance, solar, aerospace, filtration, medical, body armor, and apparel industries.

Additional Information Available

To learn more about Sonobond's ultrasonic bonding and welding equipment-or to make arrangements to take advantage of the company's free, no-obligation Ultrasonic Welding Viability Test-visit or call toll free 1-800-323-1269. For immediate service, contact President Janet Devine at


Janet Devine



1191 McDermott Drive, West Chester, PA 19380

Phone: 610-696-4710

Fax: 610-692-0674



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