"Mechanical assembly involves several steps if the wire is spliced using the clip and solder method," Cresnik says. "With ultrasonic welding, there is no secondary operation, and no need for solder or mechanical terminals. As a result, we have increased productivity and reduced cost."

To make a splice, the wires are securely clamped between suitable tools, and ultrasonic energy vibrates the tools at a right angle to the clamping force. Ultrasonic energy is applied to the wires in shear. This is required for welding metals ultrasonically and creates a true metallurgical bond that results in a low-resistance splice. The splice is welded in a single operation. Three wires are spliced in the Axiom application, but the welder can also join up to 10 stranded wires from a flat, flexible circuit to multiconnection terminals in a single operation. Wires can also be welded to terminals with appropriate tooling.