Battery & Ultrasonic Welding
Continuous Ultrasonic Metal Wire & Battery Tab Welding Calculator
Calculate acoustic energy density ($E = 15-35 ext{ J/mm}^2$), knurl pyramid tooth pitch, clamping tonnage, and solid-state diffusion parameters for lithium pouch cell multi-layer foil stacks and busbars.
1. Input Parameters
Active knurled sonotrode contact footprint (e.g. 5mm x 7mm).
2. Calculation Results
Target Energy Density (E_weld)
0.0 J/mm²
Total Weld Energy (W)
0 Joules
Sonotrode Knurl Pitch (p)
0.0 mm
Foil Stack Compaction (%)
0%
3. Geometric Visualizer
Tooling & Vector Prepress Engineering Notes
Ultrasonic Metal Welding (UMW) Physics: High-frequency lateral shear vibrations (20–40 kHz, 20–60 µm amplitude) scrub away surface oxide films under static clamping pressure. Solid-state atomic bonding occurs across microscopic asperities below metal melting temperatures, preventing brittle intermetallic phase formation.
Sonotrode & Anvil Vector Toolpaths: Sonotrode tip vector designs require precision CNC wire-cut 90° pyramid knurls with pitch 0.8–1.2 mm and flat crest lands (0.10–0.15 mm) to grip top foils without perforation tearing.