Ultrasonic Metal Roll Welding Technology

Ultrasonic metal roll welding is a solid-phase connection technology based on high-frequency vibration friction. Its principle is to convert electrical energy into high-frequency vibration energy (usually 20kHz-40kHz) through an ultrasonic generator, and transmit the vibration to the contact surface of the metal workpiece with the help of a roll welding head. Under the action of pressure, friction heat and plastic flow between molecular layers are instantly generated, thereby achieving seamless bonding of metal materials. Compared with traditional arc welding or laser welding, this technology does not require high-temperature melting of metal, avoids material oxidation, deformation and spatter problems, and is particularly suitable for precision welding of lightweight alloys such as aluminum, copper, and titanium.

Application scenarios: New energy vehicles and 3C electronics become core tracks

In the field of new energy vehicles, ultrasonic roll welding technology is widely used in key links such as power battery tab welding and battery module packaging. Taking a leading battery company as an example, after adopting the ultrasonic roll welding process, the battery module yield rate has increased to 99.7%, and the welding efficiency has increased by more than 30% compared with the traditional method. In addition, since there is no need to add solder, the conductivity and safety of the battery components are significantly optimized, which provides a guarantee for the large-scale production of high-endurance battery packs.

The consumer electronics industry also benefits from this technology. The welding of precision components such as ultra-thin metal shells and flexible circuit boards (FPCs) is extremely sensitive to heat input, and the "cold processing" characteristics of ultrasonic roll welding can accurately control the heat-affected zone and avoid the performance degradation of microelectronic components due to high temperature. According to industry reports, the global market size of ultrasonic welding equipment in the 3C electronics field will exceed US$1.2 billion in 2025.

Industrial upgrading: Domestic technology breaks the international monopoly

For a long time, the high-end ultrasonic welding equipment market has been dominated by European, American and Japanese companies. In recent years, domestic scientific research teams have overcome core technical difficulties such as "vibration system stability optimization" and "multi-material adaptive welding" through independent research and development, and successfully realized the iteration of domestic equipment. At present, domestic ultrasonic roll welding equipment has been exported to manufacturing powerhouses such as Germany and Japan. The price of a single unit is 40% lower than that of imported products, which has driven the equipment investment cost of downstream companies to drop by nearly 60%.

Industry experts pointed out that with the advancement of the "dual carbon" goal and the planning of the green manufacturing system in "Made in China 2025", ultrasonic metal roll welding technology is expected to cover more than 30% of traditional welding scenarios within five years, providing a "Chinese solution" for the low-carbon transformation of the global manufacturing industry.