The new WeldMAX Model MH-15100 from Sonobond is the industry’s largest, most powerful, and most rugged ultrasonic spot welder. It operates at 15 kilohertz and delivers up to 10,000 watts of output power to weld heavy-gauge wire bundles with a cross-section of up to 200 square millimeters. The machine can be used for wire-to-wire and wire-to-terminal assemblies. It easily handles similar and dissimilar nonferrous metals, including copper, aluminum and nickel. It can usually complete a weld in less than 3 seconds. Like other Sonobond metal welders, it can join tinned wires in one pulse and without pre-cleaning.

The machine can be used to weld high-voltage terminals for EV batteries and charging stations. It meets the industry standard USCAR 38.

The welder can accommodate special tooling, fixtures, rotary indexing tables and feeders to assemble wire harnesses, bus bars, ignition modules, starter motors, capacitors, electrical contacts and circuit breakers. 

The welder features automatic frequency control for stable operation; overload protection; quality control to detect when variables exceed preset power and time limits; the ability to detect missing or incorrect parts prior to welding. It can store 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 that can perform up to 50,000 welds before easy removal and replacement. The welder requires minimal operating and training costs, and can be incorporated into automated assembly equipment. This energy-efficient machine does not require fluxes, filler materials, or other consumables to complete a weld.

It 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 more than 60 years ago. 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. 

The system maximizes metal welding effectiveness by eliminating bending stress caused by other ultrasonic metal welders, achieving more durable joints than crimping or soldering, and eliminating metallurgical changes, such as porosity and intermetallics, that can be found in fusion welds.