Ultrasonic Welding for Busbars: Fast, Reliable and Low-Resistance Connections

Ultrasonic welding ensures extremely strong and reliable connections — even for demanding applications in electromobility, power electronics or energy distribution. The connection is created by high-frequency mechanical friction under pressure without melting the material. The result: a tight connection with excellent electrical contact.

Compared to other joining methods like laser welding or soldering, ultrasonics is particularly convincing due to its high mechanical strength: Busbars welded with ultrasonics can withstand enormous forces — both in the shear and peel direction. Depending on the application, tensile forces of 5,000 N to 10,000 N and more are possible. The connection remains stable even during temperature cycles and vibrations, making it ideal for safety-critical applications.

Another advantage: the structured surface of the welding tools ensures that oxide layers of the metal parts are effectively fractured at the contact point. This results in an extremely low contact resistance, which ensures long-term electrical conductivity — even with mixed connections such as copper-aluminum.

For engineers and process owners, this means reliable, durable connections that meet the highest requirements in industrial production — without any additives and minimum thermal stress on the material.

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Yes, ultrasonics are perfectly suited to permanently join different non-ferrous metals together. Unlike thermal processes, where different melting points and material properties often lead to problems, ultrasonics can be used to join mixed metals such as copper-aluminum or brass-aluminum firmly and reliably.

The welding process is purely mechanical – without melting, without solder. This effectively breaks up oxide layers, creating a highly conductive, corrosion-resistant joint. This is a decisive advantage, especially in electromobility and power electronics.

Ultrasonic welding is therefore the ideal solution for busbar applications that need to be connected with different non-ferrous metals.

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Modern ultrasonic welding machines are ideal as ergonomic manual workstations or as integrated systems in automated production lines. The patented architecture of the ultrasonic components enables welding with minimum cooling times, so that even thicker busbars of up to 6 mm can be welded in the shortest possible time.

Thanks to short welding times and the precise control of welding parameters, the process is perfectly suited for automated production. Each individual weld is closely monitored — up to 150 pieces of data are available per process. This data can be used for further process optimization and quality control.

Individual welding machines used in manual processes are designed to be user-friendly and can be loaded quickly thanks to large engagement areas. This enables cycle times of 7 to 12 seconds for smaller busbar applications.

Learn more about the benefits of ultrasonic welding for busbars in our free white paper.

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