The word “welding” evokes a particular image — the exposed flame of a torch and red hot molten metal. Metal parts are heated to a liquid state to join them to one another. For small scale and electrical products, this isn’t a viable bonding method. Ultrasonic welding allows a bond to form between metals, without requiring the metal to leave the solid state.
Dave Krysiak, North American sales manager for ultrasonic metal welding at Sonics & Materials Inc., explains that ultrasonic metal welding uses friction created by high-frequency vibrations to create a bond without requiring the metals to become molten.