Collaborating on ultrasonic metal welding

A series of extensive trials were carried out at Telsonic’s UK facility in Poole and the company’s headquarters in Switzerland, to determine the power requirements and tool face designs which would be needed to cover the full scope of the project.

Now on site at Warwick, the system includes a Telsonic MPX50-1 linear ultrasonic metal welder, powered by the company’s SG22 series generator, which operates at 20kHz and has an output of up to 6.5kW.  

The MPX50-1 metal welder has the capacity to apply a force of up to 5000N, with an adjustable stroke between 1 and 50mm. An integral load cell and linear encoder system are used to provide force and positional feedback, which are displayed together with process parameters on a TSC5 Controller with touchscreen graphical user interface. The TSC5 offers a choice of weld modes, with quality windows, statistical process control, intuitive graphical user interface, data export using Telsonic’s own 'TelsoTools' software application and network communication. 

Warwick Manufacturing Group (WMG) will use the system, as part of an ongoing research project, to ultrasonically weld single and multi layer non ferrous laminates, used in a range of different automotive power storage and connectivity component types. Telsonic’s scope of supply includes interchangeable sonotrodes and anvils to suit the different materials and applications.

Two different tool face configurations (single and triple) were also designed, to allow comparison and evaluation of material response, strength analysis and electrical testing following welding.

Telsonic ultrasonic modules and systems offer wide choice for end users, machine builders and system integrators. The company’s range of ultrasonic modules are also designed to be 'automation friendly' allowing easy integration within stand alone systems and sophisticated production lines.