Advantages of Ultrasonic Welding for High Voltage Cables

High frequency ultrasonic vibrations are used in the joining procedure known as “ultrasonic welding” to combine two pieces of material. Metals that are challenging to weld using traditional techniques often utilize ultrasonic welding. There are several benefits of ultrasonic welding, particularly for high voltage cable welding.

Some of the main advantages of ultrasonic welding for high voltage cables include increased strength and durability, improved electrical conductivity, and enhanced aesthetics. These benefits make ultrasonic welding an ideal choice for high voltage cable assembly where safety and reliability are critical.

What is ultrasonic welding?

Ultrasonic welding was first developed in the 1940s and has since become a staple joining method in many industries. This technology welds an area of two similar or dissimilar materials together by using high-frequency ultrasonic vibrations.

The first recorded use of ultrasonic welding was in 1943 by Huffman, who used it to weld tungsten wire. In the 1950s, this technology was adapted for use in the plastics industry. By the 1970s, advances in transducer technology had made ultrasonic welding more available. Later on, it was used for metals as well.

Ultrasonic welding has been refined continuously since its inception. Today, it is considered a highly versatile joining method with many advantages.

What Is the Process of Ultrasonic Welding?

Ultrasonic welding uses high-frequency ultrasonic vibrations to weld two materials together. The resulting friction creates high heat that causes them to fuse together.

The process begins with the placement of two materials between an anvil and a horn. The anvil helps to support and position the workpieces, while the horn applies pressure and ultrasound energy to the joint area.

Once activated, the horn vibrates at a high frequency, which causes friction at the interface of the two materials. This frictional high heat fuses the materials, allowing them to flow into each other and form a bond.

The entire process takes place very quickly, typically within 2–3 seconds. After welding, the parts are allowed to cool before being removed from the fixture.

Advantages of Ultrasonic Welding for High-Voltage Cables

Ultrasonic welding provides a stronger and more durable joint than traditional methods, such as arc welding. The high-frequency vibrations create frictional heat that melts the materials being joined together. This results in a molecular bond between the materials. This makes ultrasonic welds ideal for joining dissimilar materials. Ultrasonic cable welding of large cross-sections of copper and aluminum cable to terminal are an example. This method is the most effective method for assembling advanced high voltage cables.

Improved electrical conductivity

Improved electrical conductivity is another advantage of ultrasonic welding. When two pieces of metal are joined together using traditional methods, there is always some resistance at the point of contact. This resistance can result in the loss of electrical energy as heat. Ultrasonic welding produces a seamless, resistance-free connection, resulting in improved electrical conductivity.

Enhanced Aesthetics

Ultrasonic welding also enhances the aesthetics of the finished product. Traditional methods leave unsightly joints that can detract the appearance of a well-crafted item. Ultrasonic welding produces clean, smooth seams that are invisible to the naked eye.


In conclusion, ultrasonic welding offers several benefits for high-voltage cable welding. This includes increased strength and durability, improved electrical conductivity, and enhanced aesthetics. Because of this, it is an excellent choice for assembling advanced Electric Vehicle high voltage cables, where these factors are critical.

TECH-SONIC, Inc. is the first to develop a high voltage cable welding machine that utilizes “Closed-Loop Control” ultrasonic metal welding. With the right equipment, a high-quality weld can be achieved because joining similar and dissimilar materials has never been so quick and easy!

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