Devine's contribution to Volume 6A--Welding Fundamentals and Processes --reflects her
many years of innovative leadership and exceptional expertise in the field of ultrasonic technology.
WEST CHESTR-- Pennsylvania, January 26, 2012 -- Sonobond Ultrasonics announced today that
the company's President, Janet Devine, authored the chapter on "Ultrasonic Welding" for the ASM
International Handbook, Volume 6A Welding Fundamentals and Processes,
printed in November 2011. This publication is a focused revision of the welding
information in the 1993 Volume 6 "Welding, Brazing, and Soldering," for which
Ms. Devine also contributed the chapter on Ultrasonic Welding.
ASM International, The Materials Information Society, has 36,000
members worldwide and was formerly known as the American Society for Metals.
It is a professional organization for materials scientists, engineers, metallurgists, and others working
with metals. The newly released Volume 6A is the most complete and up-to-date reference source on
welding processes available today. Copies of this expert-written and peer-reviewed publication can be
obtained by going to the Society's website at www.asminternational.org.
An Outstanding Record of Achievement
Janet Devine was born and educated in England. A graduate of the prestigious Imperial College
of the University of London, she has a B.Sc. Degree in Mathematics and Physics. Prior to coming to the
United States in 1959, she worked for Bristol Aero-Engine Group (now Rolls-Royce). She joined
Sonobond, then known as Aeroprojects, in 1960 when ultrasonic metal welding
was in its infancy. Ms. Devine has been an active participant in the development
of many of the most significant commercial and industrial uses of ultrasonic
energy for metal welding and metal forming. Before being named Sonobond's President in 1990, she served as the company's Vice President and Technical
Ms. Devine holds several patents. She has also authored numerous papers in the field of
ultrasonic metal welding, textile bonding, and ultrasonic processing (e.g., extrusion and wire drawing).
In 1991, she was a member of the committee that authored the chapter on Ultrasonic Welding for
Volume 2, Eighth Edition of the American Welding Society's Welding Handbook. Ms. Devine serves on
the Board of Directors of the Ultrasonic Industry Association (UIA) and was President of that
organization from 1997-1999. In describing her reaction to being asked to contribute the chapter on
Ultrasonic Welding for the new ASM handbook, she said, "I was honored to be of service in this way. I
was also pleased to once again to be working with Karl Graff of the Edison Welding Institute, who
authored the chapter on ultrasonic additive manufacturing that follows mine in the new handbook."
Ultrasonic Metal Welding Offers Important Advantages
Ultrasonic metal welding is a solid-state welding process that uses localized high-frequency
vibratory energy in conjunction with moderate clamping force. It does not require consumables -- such
as welding rods, fluxes, fillers, or solders -- or special cleaning methods. This energy-efficient,
environmentally-friendly system produces no arcs or sparks. It is ideal for joining non-ferrous dissimilar
metals, for welding thin sections to thicker sections, for joining multiple layers of thin materials, and for
welding through most oxides and surface oils. Ultrasonic metal welding produces strong joints that have
good thermal and electrical conductivity. Only a modest amount of space is needed for the equipment.
The first patent ever issued for ultrasonic metal welding was awarded to Sonobond Ultrasonics
(then called Aeroprojects) in 1960. Since then, the company has continued to be a worldwide leader in
the development of ultrasonic metal welding equipment. This technology offers significant energy costsaving
advantages when compared to other bonding methods. According to President Devine, "Our
equipment not only produces superior metal welds, it also generates important savings in comparison to
such methods as resistance welding and soldering. This makes it win-win for manufacturers because
they can generate fast, reliable welds while, at the same time, reducing what they have to spend on
energy and other production costs." According to Ms. Devine, energy consumption with Sonobond
equipment is substantially less than with resistance welders. For example, manufacturers with multiple
installations of resistance welders may require a new electrical substation to handle their requirements.
On the other hand, ultrasonic welding equipment can usually be accommodated with standard power
The advantages of ultrasonic metal welding are particularly noteworthy in the assembly of wire
harnesses for automotive and similar applications. Resistance welders need 20 times more energy than
ultrasonic welders. They may also require water cooling, which can be both costly and necessitate
treatment of the water before it can be returned to the water supply. Yet it only takes about the same
amount of time to make an ultrasonic weld as it does to produce a resistance weld. Wire harness
manufacturers also report that ultrasonic welding reduces the expense of attaching copper wires by 50%
over old crimp and solder methods. In addition, ultrasonically welded joints are stronger, have better
electrical conductivity, and weigh less without the mechanical crimp.
Wedge-Reed Design and Other Sonobond Advantages
After proudly pointing out that Sonobond"s ultrasonic metal welders are all manufactured in the
U.S.A., President Devine went on to cite several other factors that help make this technology such an
excellent choice. She said, "We design our equipment in ways that help manufacturers reduce costs.
For instance, Sonobond machines are easy to operate and require only minimal training. Our
microprocessor-controlled ultrasonic welders can set and recall up to 250 weld protocols from memory.
Welding can be controlled by height, energy or time. All this substantially reduces the possibility of
costly mistakes on the part of machine operators.
"There are also built-in features that provide meaningful savings to our customers. For
example, all Sonobond metal spot welders use the patented Wedge-Reed System that combines high
vibratory force with low amplitude coupling for maximum metal welding effectiveness. This system uses
heat-treated, tool steel Taper Lock Tips that are manufactured to last for up to
100,000 welds. When the tips finally do need to be replaced, this can be done
quickly and easily on our machines. However, ultrasonic metal welders
manufactured by some other companies may require replacement of the
entire horn, not just the tip. This can be much more expensive in terms of
downtime and labor costs. But that's not all. Only the Sonobond ultrasonic system is capable of welding
most oxidized and tinned metals. This is another important reason so many companies specify
Sonobond Has an Ultrasonic Metal Welder for Practically Every Application
During her long career at Sonobond, Janet Devine has played a critical role in overseeing the
development of ultrasonic metal welders for a wide variety of uses. These applications include:
Assembly of wire harnesses and heavy-duty cables for cars, trucks, and industrial machinery.
Sonobond equipment can weld wire bundles with cross-sectional areas of up to 100 square
millimeters, even with lightly tinned or oxidized wires. It is unique in its ability to accomplish
this with a single pulse.
Advanced battery and super capacitor applications involving up to 80
layers of foils even if lightly tinned. The dual-head system can also weld
3 millimeter-thick, non-ferrous sheet metal when equipped with
Assembly of the solar cells that constitute solar panels. Sonobond
equipment is perfect for welding aluminum strips to the metalized glass
on PV modules. The resulting interconnects between the PV cells create
an array with excellent conductivity.
Welding of larger metal parts, such as those used in the automotive
industry. The "C-frame" units virtually eliminate the problem of tips
sticking to aluminum parts and can be equipped for use on large
Spot welding --including wire-to-terminal welding -- in a single pulse.
Sonobond ultrasonic metal welders are ideal for bus bar fabrication, as
well as for welding stranded wire to brass or copper terminals and
producing single point ground terminals.
Fast, clean splicing of thin aluminum and copper foils up to 0.004" (0.1 mm) thick and up to 48"
wide. Our system consists of a power unit with a solid-state converter, a welding head, and a
rotating disk tip which transverses the width of the foil at speeds up to 15 feet per minute. This
technology is found in practically all U.S. foil mills.
The industry's most powerful spot welder with a full 4,500 watts of output for welding heavy
gage wire to terminals, ignition module plates, and other electronic/electrical assemblies. The
welded joints are often stronger than the parent metals, and the process usually takes less than
Portable, hand-guided tube closure for precisely crimping and sealing copper and aluminum
tubing. This one-step process creates quick, airtight seals without brazing and can
accommodate tubes already charged with coolant, fluids, and gasses.
A Proud Past and a Promising Future
In looking back on Sonobond's record of leadership, President Devine says, "It has been very
gratifying to see how ultrasonic metal welding has gained acceptance -- and even a certain amount of
prestige -- over the decades. Time and time again, manufacturers across a wide variety of fields have
found this process to be an extremely costÂ©effective and reliable solution to their needs. I'm also proud
of Sonobond's part in finding new applications in evolving industries. These include significant
innovations in the EV vehicle, solar, battery, electrical, and cable industries. At the same time, our
equipment continues to improve in terms of power capacity, reliability, and better control functions."
Although recent economic conditions have kept some companies from investing in new
equipment, Ms. Devine believes there will be pent-up demand as things improve. She says, "We see
more applications for ultrasonic welding and a greater acceptance of its use in a range of niche
industries. We also anticipate that robotics will mean increased utilization of ultrasonics for welding
aluminum and other lightweight sheet metals. This is especially true among automotive and battery
manufacturers. Sonobond is very optimistic about the future of ultrasonic metal welding and firmly
committed to maintaining its leadership role in this growing field."
In addition to its complete line of ultrasonic metal welders, Sonobond offers ultrasonic
equipment for nonwovens/textile and plastic applications. Among the company's many customers are
leading firms in the electrical, automotive, appliance, solar, aerospace, filtration, and apparel industries.
Additional information about Sonobond's ultrasonic metal welding equipment can be obtained
by visiting www.SonobondUltrasonics.com. For questions or immediate service, please email Vice
President Melissa Alleman at MAlleman@SonobondUltrasonics.com or call 1-800-323-1269.