The Axiom Group (Aurora, Ontario, Canada) manufactures wire harnesses and plastic components for automotive door mechanisms. When the firm launched its electronics division in 2000, it sought an alternative to crimping and soldering for splicing wires in wire harnesses. John Cresnik, general manager, had previous experience with mechanical crimping and soldering. He decided to use ultrasonic metal welding in the new operation. Axiom then purchased an MH2015D ultrasonic metal spot welder from Sonobond Ultrasonics (West Chester, PA).

"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.

The welder is equipped with an energy controller to ensure weld quality. "The setup operator can set weld parameters by time and energy," Cresnik says. "If a weld falls outside the preset limits, an alarm alerts the operator to an incorrect weld. Also, weld protocols can be changed as needed without downtime."

For more information on ultrasonic metal welding, call 800-323-1269or visit www.sonobondultrasonic.com.