Ultrasonic Metal Welding for Lithium Battery Tabs & Foil Stacks

Q: How many layers of copper and aluminum foils can be welded simultaneously?

Our 20kHz 3000W-5000W systems routinely weld up to 80-100 layers of 6-10 µm copper foil or 12-15 µm aluminum foil directly to solid copper or aluminum tabs in a single 0.4-0.8 second cycle.

Q: How do you prevent foil tearing under the ultrasonic horn?

We utilize micro-knurled sonotrode welding tips with radius-profiled tooth geometry and multi-stage pressure profiling to eliminate stress concentration.

Q: Can we send battery tab samples for trial welding?

Yes. Ship raw foil stacks and busbars to our Zhaoqing testing lab. We execute tensile shear and micro-ohm resistance testing with full 4K video documentation within 48 hours.

EV Battery & Energy Storage Manufacturing

Ultrasonic Metal Welding for Lithium Battery Tabs & Multi-Layer Foil Stacks

Solid-state metallurgical joining for multi-layer copper and aluminum foil stacks (up to 80–100 layers), pouch cell tab-to-busbar connections, and cylindrical cell nickel ribbons. Zero melt spatter, lowest electrical contact resistance, and zero thermal degradation.

Industrial Ultrasonic Metal Welder for EV Battery Tabs and Foils

Figure 1: UltraLanank 20kHz 3000W heavy-duty ultrasonic metal welding system bonding lithium battery foil stacks to nickel-plated copper busbars.

1. The Ultrasonic Metal Welding Advantage: Solid-State Atomic Diffusion

Traditional laser or resistance welding of copper and aluminum foils creates fragile intermetallic compounds (e.g., $CuAl_2$), thermal heat-affected zones (HAZ), and hazardous molten metal spatter that can puncture battery separators.

Ultrasonic metal welding operates via high-frequency lateral shear scrubbing (20kHz, 25–45 µm amplitude) under pneumatic clamping. The friction disperses surface oxide films, creating atomic diffusion lattice interlocking without melting the base metals. The result is superior electrical conductivity, tensile peel strength exceeding base metal limits, and near-zero electrical contact resistance (<0.05 mΩ).

2. Recommended Equipment & High-End Tooling

20kHz 3000W Ultrasonic Wire Harness & Battery Metal Welder (UL-MW3000): Features real-time dynamic energy/power monitoring, knurled hardened steel anvils, and precision height control.
Explore our specialized Ultrasonic Metal Welding & Tooling Systems Catalog for high-tonnage busbar and terminal welders.

3. Battery Metal Welding Technical FAQ

Q: How many layers of copper and aluminum foils can be welded simultaneously?

A: Our 20kHz 3000W–5000W systems routinely weld up to 80–100 layers of 6–10 µm copper foil or 12–15 µm aluminum foil directly to solid copper or aluminum tabs in a single 0.4–0.8 second cycle.

Q: How do you prevent foil tearing under the ultrasonic horn?

A: We utilize micro-knurled sonotrode welding tips with radius-profiled tooth geometry and multi-stage pressure profiling to eliminate stress concentration.

Q: Can we send battery tab samples for trial welding?

A: Yes. Ship raw foil stacks and busbars to our Zhaoqing testing lab. We execute tensile shear and micro-ohm resistance testing with full 4K video documentation within 48 hours.