BRONSCHHOFEN, Switzerland—Telsonic AG, a leading supplier of ultrasonic welding equipment for electric vehicle assembly applications, has produced a poster that covers common wire splicing and wire termination welding applications. Important quality and operational criteria are highlighted using text and images, together with test criteria and a useful table of wire sizes.

The large poster is based on existing industry specifications and input from Telsonic customers.

“Access to this user-friendly guide will enhance confidence in the operation of ultrasonic technology for metal welding, which in turn will enhance consistency and quality on every application,” says Gustavo Garcia-Cota, managing director of Telsonic.

“Wire harness assembly manufacturers must adhere strictly to industry standards if the highest levels of quality are to be attained and maintained,” notes Garcia-Cota. “The current standards for ultrasonic wire splicing and termination have been developed globally by both industry OEMs and their Tier One suppliers. Recent standards starting to be used commonly are SAE/USCAR 45 for wire splicing and SAE/USCAR 38 for wire termination.

“There are several opportunities to follow best practice guidelines for ultrasonic welding—

initially during trials in the laboratory and ultimately in the production plant environment where process validation takes place,” explains Garcia-Cota. “Necessary information and easily accessible visual display for quick reference can be very effective for [both assemblers and engineers].”

To obtain a copy of the "Ultrasonic Metal Welding Quality Guidelines" poster, email sales.boston@telsonic.com.