Aluminum wires are widely adopted in new energy wire harness production thanks to their light weight and cost-effectiveness. However, aluminum is soft and prone to surface oxidation, which commonly causes welding head adhesion, uneven welding points and low yield rate during production — major pain points across the industry.
To address these issues, HIMINSEN has developed a complete customized solution combining material science and acoustic technology:
welding sample
- Adopt high-hardness wear-resistant dedicated welding heads to enhance anti-adhesion performance and extend service life;
- Integrate an intelligent parameter matching system to automatically adjust welding power and amplitude according to wire gauge and material;
- Equip with a dynamic pressure compensation module to offset errors caused by material deformation and ensure stable welding points.
Verified by extensive on-site tests, this solution raises the yield rate of aluminum wire welding to over 99.5% and extends the service life of welding heads by 3 to 5 times. It is perfectly applicable to aluminum wires (6-95mm²) and dissimilar metal terminal welding of copper and aluminum. The technology has been put into practical use by many leading manufacturers. Meanwhile, we keep cooperating with universities on R&D to continuously optimize welding processes.
#Technical Sharing | Professional Solutions to Welding Head Adhesion in Aluminum Wire Ultrasonic Welding – HIMINSEN
#Aluminum wire ultrasonic welding #difficulties in wire harness welding # solutions to welding head adhesion # high-voltage aluminum wire harness welding
📩For more information, please feel free to contact us:
📧Email: delin@himinsens.com
📞Tel: +8618938694287
📍Address: 101, Building 8, Jin’an Building, Shangcun, Gongming Street, Guangming District, Shenzhen,China
