Sonobond's Joe Walsh Receives a 2011 Technical Achievement Award for His Important Role in Developing the Dual Head SpliceRite(TM) Ultrasonic Wire Splicer

Wire & Cable Technology International Magazine honored Walsh for his work on this Sonobond welder that quickly and reliably splices wire bundles with cross-sectional areas up to 100 sq. mm. No other ultrasonic welder equals this capacity with just one hit. Even lightly tinned or oxidized wires can be accommodated.

WEST CHESTER, Pennsylvania, November 22, 2011 - Melissa Alleman, Vice President of Sonobond Ultrasonics, announced today that Joe Walsh, the company's Director of Machine and Tooling Design & Development, has received a 2011 Technical Achievement Award from Wire & Cable Technology International. In making the announcement, Vice President Alleman said, "These prestigious awards are made annually to select individuals for their major contributions to the wire and cable industry. Joe was honored for his years of innovative work in the field of ultrasonic wire splicing technology, most especially for his noteworthy part in developing Sonobond's Dual Head SpliceRite(TM) Wire Splicer. This ultrasonic metal welder represents a significant technological breakthrough because it provides fast, dependable splicing of wire bundles with cross-sectional areas of up to 100 square millimeters. The weld is accomplished with just one pulse. No other ultrasonic metal welder equals this capacity."

Leadership in Dual Head Technology

Joe Walsh, a graduate of Penn College of Technology, has been with Sonobond for 25 years. He is a Certified Welding Technician and currently working towards a degree in Mechanical Engineering.

In the years between 2004 and 2008, Sonobond Ultrasonics was involved in a joint venture with Ford Motor Company and others that led to a major innovation in ultrasonic metal welding. During this period, the automotive industry was looking for ways to weld various aluminum alloys at sheet thicknesses up to two layers of 3 mm each. However, the available power level was limited. This necessitated a lengthy weld time that caused sticking between the welding tip and the aluminum. Mr. Walsh played a big part in solving this problem by developing Sonobond's Dual Head Spot Welder. This ultrasonic welding system introduced energy to both sides of the weldment. As a result, the desired thickness of metal was accommodated, the welding time shortened, and the problem of tip sticking substantially reduced.

Dual Head SpliceRite(TM): Ideal for Wire Harness Applications

In recounting what came next, Vice President Melissa Alleman says, "It was only natural for us to ask Joe to apply his success with the Dual Head Spot Welder to ultrasonic wire splicing. This led to the development of Sonobond's Dual Head SpliceRite(TM) Ultrasonic Wire Splicer."

Ultrasonic welding is a well-accepted and frequently used method of assembling wire harnesses. It creates solid-state metallurgical bonds that have high conductivity. This is accomplished without producing arcs, sparks, or fumes and without melting the weldment. However, the Dual Head SpliceRite(TM) is significant because it greatly extends welding capacity. It does this with two ultrasonic welding heads, one on each side of the welding area. This innovation permits stranded copper wire - with cross-sectional areas of 48 to 100 sq. mm. - to be welded in a single pulse. No other ultrasonic unit can equal this capacity with just one hit. Even tinned wires up to 60 sq. mm. can be accommodated without pre-cleaning. Ms. Alleman explains further, "The Dual Head SpliceRite(TM) offers significant advantages by eliminating the need for filler materials, clipping, soldering, crimping, or dipping. This environmentally - friendly, cost-effective process produces no waste and consumes only minimal energy. It is especially suitable for assembling the heavy cables used for cars, trucks, and industrial machinery."

The Dual Head SpliceRite(TM) consists of two ultrasonic transducers and couplers, one above and one below the wire bundle, and a set of pneumatically driven jaws. These jaws gather the wires tightly to a preset width. The upper tip then descends to complete the compressing of the bundle and ultrasonic power is applied. When the cycle ends, the jaws open so the wires can be removed. A support for the wire array can also be integrated into the tooling system if necessary.

Advantages of Sonobond's Wedge-Reed System

All Sonobond spot welders, including the Dual Head SpliceRite(TM), use the unique, patented Wedge-Reed bonding system of high vibratory force and low amplitude coupling. Shear mode vibration, parallel to the welding surface, is utilized while the line of force is directly over the parts to be welded. This creates precise, dependable welds without bending stress or stalling. It also enables most oxidized and tinned metals to be spliced with one pulse and without pre-cleaning. No other ultrasonic metal welding system can weld oxidized or tinned surfaces.

The Dual Head SpliceRite(TM) features heat-treated, tool steel taper lock tips that can last for 100,000 welds or more. These are designed for quick tooling changes and fool-proof placement. The equipment has a 3500-watt power supply with a microprocessor that stores and recalls up to 250 jobs. Welds can be controlled by height, by energy, or by time. The entire process is completed quickly and does not melt the material. According to Vice President Alleman, "Joe Walsh's work in developing the Dual Head SpliceRite(TM) has enabled us to add yet another innovative machine to our impressive line of cost-effective, environmentally-friendly metal welders. And like our other Sonobond equipment, this ultrasonic wire splicer can be operated easily with only minimal training."

Over 50 Years of Innovation

In 1960, Sonobond-then known as Aeroprojects-received the first patent ever awarded for ultrasonic metal welding. Over the intervening fifty - one years, Sonobond has continued to enjoy a well - earned reputation for its pioneering work and quality-engineered products. The company currently manufactures a complete line of ultrasonic welding and bonding equipment for companies in the automotive, appliance, solar, electrical, filtration, aerospace, medical, body armor, and apparel industries.

Free Ultrasonic Welding Viability Test

Sonobond is firmly committed to helping companies find practical, effective solutions to their ultrasonic welding requirements. With that in mind, it offers an Ultrasonic Welding Viability Test to help determine which machine is right for each specific application. Companies are encouraged to submit their materials to have sample welds made. There is no cost or obligation for this service. In addition, Sonobond backs its products with exceptional technical support and makes every effort to assure that its equipment is introduced into the production process as seamlessly as possible. Sonobond also provides outstanding customer service before, during, and after installation.

Additional Information

To learn more about the Dual Head SpliceRite(TM) Ultrasonic Wire Splicer, the Dual Head Spot Welder, other Sonobond equipment, or the free, no-obligation Ultrasonic Welding Viability Test, visit or call 1-800-323-1269. For immediate service, contact Vice President Melissa Alleman at

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