Metal welding

Metal welding is used in the automotive and electronics industries to produce batteries, cable connections, etc. In metal welding, metals are welded in high temperatures, for instance. We differentiate between metal active gas (MAG) and metal inert gas (MIG) welding. AActive gases form a connection with the metal, inert gases do not. In ultrasonic welding, ultrasonic waves are used to join the metals.

Advantages of metal welding using ultrasonics

Ultrasonic welding is mainly suitable for copper and aluminum connections. The process requires little energy and is fast. Components joined by ultrasonic metal welding equipment have high strength and excellent electrical conductivity, since the vibrations destroy oxide layers and remove impurities on metal surfaces. Contact resistances, such as those taking place during soldering or crimping do not occur. Reproducibility of the process sequences is important for precise and efficient production with a high degree of quality monitoring. The quality of ultrasonically welded connections therefore heavily depends on application-specific process development. In the laboratory at Herrmann Ultrasonics, we systematically determine the optimum process parameters for your ultrasonic weld task and design the perfect weld system for your production environment.

Ultrasonic welding offers numerous advantages over conventional metal welding:

  • Environmentally friendly: The weld process requires less energy compared to classic types of metal welding.
  • Precise: Ultrasonic welding is precise. This is important above all when welding very small metal parts, e.g. in batteries.
  • Gentle: Ultrasonic welding works without extremely hot temperatures. This ensures that the metals and other materials are not damaged.
  • Cost efficient: Ultrasonic welding is fast and does not require any additional tools such as solder.
Application Engineering

Application solutions for nonferrous metals

ultrasonic welding process solutions in battery management
ultrasonic welding in use cable terminal
ultrasonic welding in use cable terminal
process ultrasonic welding of metal foils
ultrasonic welding in use cable terminal


AUTOMOTIVE, BATTERY pdf 2 MB pdf 1 MB pdf 2 MB
perfect product

Ultrasonic welding machines and systems

Application engineering

Industry solutions

The Herrmann Family of Ultrasonic Metal Welders

Our line of ultrasonic metal welders is ideal for welding battery components, cables, and terminals in the automotive, electronics, and energy sectors. At Herrmann Ultrasonics, we produce specific machines optimized for each of these tasks.

HiS VARIO B is great for the ultrasonic welding of copper or aluminum as part of battery assembly. Designed for either integration into automated equipment, or manual operation, this product provides patented, accurate and repeatable sonotrode alignment and quick tool changes. EtherCAT, PROFINET IO and EtherNet/IP interfaces are available.

For ultrasonic welding aluminum or copper cable to terminals, consider HiS VARIO W. This too is offered as a manual workstation or automation integration. Quick, reproducible tool change and precise sonotrode alignment for quality results across various assemblies. Large gauge cables up to 95 mm2 can be welded.

Terminal welding is addressed by HiS VARIO T. Busbars and power distribution assemblies are quickly adapted in this modular design.

The heart of all Herrmann Ultrasonics’ machines is the ULTRAMETAL digital ultrasonic generator. Intended for intermittent applications, this product is available in 20 and 35 kHz frequencies with power from 1200W to 6200W. Whenever you’re trying to find an ultrasonic metal welder for sale, make sure this is the generator it uses.

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André Deponte and Team
André Deponte and Team