3pin Auto Plug to Relay Cable Assembly

01 This custom wire assemblies processed with special copper ultrasonic welding for wire joint connection, which replaced common splice PNT terminal. Ultrasonic welding does not require flammable fuels and open flames, so compared to other welding methods, it's a safer process. Workers are not exposed to flammable gases or noxious solvents. In electronics, copper wires are usually bonded to electrical contacts on circuit boards with solder. The same task can be done using ultrasonic welding in a fraction of the time and without exposing workers to fumes from smoldering lead solder.

Advantages of Ultrasonic Welding :
1. Dissimilar metals may be joined.
2. High quality weld is obtained.
3. The process can be integrated into automated production lines.
4. Moderate operator skill level is enough.
5. The process is fast, economical and automated.
6. It is used in mass production up to 60 parts per minute.
7. It ensures increased flexibility and versatility.
8. Very thin materials can be welded.

As said, even ultrasonic welding processing has many advantages, Ultrasonic welding does have its limitations,

Limitations of ultrasonic Welding :

1. Only small and thin parts may be welded.
2. Work pieces and equipment components may fatigue at reciprocating loads provided by ultrasonic vibration.
3. It is not suitable for ductile materials since they yield under the stresses.
4. It needs specially designed joints.
5. Ultrasonic vibrations can damage electrical components.
6. Tooling costs for fixtures are high.