Matt Bloss

Ultrasonic metal welding, around since the 1950s, has proven itself useful in a variety of industries where joining applications involve thermally conductive materials. While the process does have its disadvantages—joint configurations, thickness limitations, and difficulty welding high-strength materials, to name a few—ultrasonic metal welding has a bright future with the rising popularity of lightweight materials in the automotive and aerospace industries. This overview of the process will outline the principles of ultrasonic metal welding, describe the key weld process parameters, and note a number of process applications.