Sonobond Ultrasonics has announced that its latest metal welder, the WeldMAXTM Model MH-15100, is the largest, most powerful, and most rugged ultrasonic metal spot welder in the industry. It operates at 15kHz and delivers up to 10,000 watts of output power to weld heavy gauge wire bundles up to 200mm2 cross-section area for wire-to-wire and wire-to-terminal assemblies. It easily handles similar and dissimilar nonferrous metals, including copper, aluminum and nickel, usually completing the weld in less than three seconds. Along with all other Sonobond metal welders, it is the only ultrasonic metal welder that can join tinned wires in one pulse, and without pre-cleaning.
Wire welding of up to 200mm2 cross-section area allows for assembly of the large gauge wire that EV manufacturers often use in producing the high-voltage terminals in EV batteries and EV charging stations. Importantly, WeldMax welds meet the United States’ car industry standard, USCAR 38.
Sonobond’s WeldMAXTM – Industry’s Most Powerful Ultrasonic Metal Welder – Page 2.
The welder can accommodate special tooling, fixtures, rotary tables or feeders to produce electrical wire harnesses, bus bars, ignition modules, starter motors, capacitors, electrical contacts and fuses/circuit breakers.
The MH-15100 features automatic frequency control for stable operation, overload protection, quality control to detect when variables exceed preset power and time limits, detects and prevents wrong-part or no-part welding, and can store and recall up to 250 weld protocols. Sonobond’s Advanced HMI also enables the welder to provide both pre-weld and post-weld height measurements.
The welder features heat-treated, tool steel Taper Lock Tips which can perform up to 50,000 welds before easy removal and replacements. The welder requires minimal operating and training costs, and can be incorporated into automated assembly equipment. It is energy efficient, and has no need of fluxes, filler materials, or other consumables to complete a weld.
The WeldMAXTM utilizes downward force directly over the weld center along with a shear mode vibration that is parallel to the welding surface. This is the “Wedge-Reed” System for ultrasonic metal welding that Sonobond invented and patented over 60 years ago. Unlike any other ultrasonic metal welders, The Wedge-Reed coupling system combines low vibratory amplitude power with high vibratory clamp pressure to create strong, precise, solid-state metallurgical bonds without melting the materials.
This System maximizes metal welding effectiveness by eliminating bending stress caused by other ultrasonic metal welders, achieving more durable welds than crimp or solder methods, and eliminating metallurgical changes such as porosity and intermetallics that can be found in fusion welds.
For more information, please visit the website or contact Sara Karmilowicz at 610-696-4710, 800-323-1269, or [email protected].
