Ultrasonic Wire Harness Welding | Demonstration of Solid-State Welding Process for Multi-Strand Copper Wires
2026-08-05 00:00:00
2
Welding Type
Ultrasonic wire harness welding joins multiple copper wires in a solid state through high-frequency vibration, without solder or flux.
Process Specifications
| Frequency | 20 kHz |
|---|---|
| Welding power | 2,000 W |
| Welding time | 0.25–0.5 s |
| Amplitude | 40–60 μm |
| Wire range | 0.5–10 mm² stranded copper wire |
| Weld bonding rate | ≥90% |
| Tensile strength | ≥85% of the wire-body strength |
| Internal resistance | ≤0.5 mΩ |
Process Advantages
Compared with soldering, the process requires no preheating, produces no solder spatter, and needs no flux cleaning. A single-point welding cycle is about 0.3 seconds, improving efficiency by more than five times.
It is suitable for mass production of automotive, home-appliance, and industrial-control wire harnesses.
Sample Display
The gallery images show actual multi-strand copper-wire welding samples.