Ultrasonic Welding

National Laboratory: 
Oak Ridge National Laboratory
Processing/Manufacturing Class: 

Oak Ridge National Laboratory has a unique capability for joining similar and/or dissimilar materials known as ultrasonic welding (UW). UW is a solid-state joining process, where high-frequency ultrasonic vibrations are locally applied to workpieces by a vibrating tool “sonotrode,” held under pressure. Joining is made by frictional heat generated at the interface between the parts or surfaces.

Capability Bounds: 

The machine can join different material combinations with various material thicknesses. An ultrasonic transducer that converts electrical power to mechanical vibratory power is at 20 kHz. The maximum powers of ORNL’s UW equipment are 2500 and 3500 watt.

Unique Aspects: 

ORNL’s unique UW capability affords low energy input with no additional filler metal required. It offers fast welding time in a clean, highly automated process. Weld bonding (with UW plus adhesive) for corrosion mitigation and increased strength also is available.


The equipment is available for various partnership arrangements with industry.

Single Point of Contact: 

Name: Dr. Zhili Feng
Email: fengz@ornl.gov
Phone: 865-576-3797

  1. Lai, W., Pan, J., Feng, Z., Santella, M. et al., "Failure Mode and Fatigue Behavior of Ultrasonic Spot Welds with Adhesive in Lap-Shear Specimens of Magnesium and Steel Sheets," SAE Int. J. Mater. Manf. 6(2):279-285, 2013, doi:10.4271/2013-01-1020.
  2. Pan, T., Feng, Z., Santella, M., and Chen, J., "Corrosion Behavior of Mixed-Metal Joint of Magnesium to Mild Steel by Ultrasonic Spot Welding with and without Adhesives," SAE Int. J. Mater. Manf. 6(2):271-278, 2013, doi:10.4271/2013-01-1017.
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