Ultrasonic Welding vs Conventional Welding

Ultrasonic welding is now becoming very popular in terms of welding needs. What kind of magic does it have that allows more and more industries to choose and apply it? This article lets us explore the differences between ultrasonic welding and conventional welding.

 What is ultrasonic welding?

Ultrasonic welding uses the piezoelectric effect to convert electrical energy into ultrasonic sound energy. The ultrasonic waves cause the welding surface to vibrate at high frequencies, melt and then combine into new molecular chains to achieve welding strength comparable to raw materials. It can be used in metal welding, plastic welding, food cutting, etc.Ultrasonic Welding vs Conventional Welding

What is conventional welding?

Traditional welding can be divided into arc welding, resistance welding, gas welding, hot melt welding and other types. Welding materials can be classified into two types based on their application: filler welding and self-flux welding.

Arc welding

Arc welding is the most widely used welding method in industrial production. It uses the welding rod and the welding metal to form two poles. When they are close to each other, an arc is generated. The heat generated by the arc discharge (commonly known as arc combustion) is used to melt the welding rod and the workpiece with each other and form after condensation. Weld seams to obtain a solid joint.

Ultrasonic Welding vs Conventional Welding

Resistance welding

Resistance welding refers to a method that uses electric current to pass through the weldment. Due to the large resistance at the welding point, resistance heat is generated as a heat source to locally heat the weldment and pressurize the welding part at the same time. When welding, no filler metal is required, the productivity is high, and the deformation of the weldment is small.

Ultrasonic Welding vs Conventional Welding

Hot melt welding

Fusion welding refers to the use of high temperatures to melt the welding surface. Since the workpieces to be welded are closely together, the molten liquid of the two workpieces will mix under the action of temperature field, gravity, etc. After condensation, the two workpieces are firmly welded together.

Gas welding

Gas welding, also known as oxygen fuel welding (OFW). A welding method that uses combustion-supporting gas (mainly oxygen) and combustible gas (mainly flame generated by mixed combustion of acetylene, liquefied petroleum gas, etc.) as heat sources to melt the weldment and welding materials to achieve interatomic bonding. The equipment is simple and does not require electricity, but it is extremely dangerous.

Ultrasonic Welding vs Conventional Welding

Advantages of ultrasonic welding compared to conventional welding

Compared with traditional welding, ultrasonic welding speed is faster and more efficient; in terms of welding safety, it is more environmentally friendly, cleaner, and safer to operate; in terms of welding cost, energy consumption is quite small, energy efficiency is higher, and it is extremely suitable for mass production; welding In terms of quality, although the welding strength is very high, ultrasonic welding will not affect the welding surface and is more beautiful. These advantages of ultrasonic welding are even more prominent in plastic welding.

Ultrasonic Welding vs Conventional Welding

Disadvantages of ultrasonic welding compared to conventional welding

Ultrasonic welding also has disadvantages compared to traditional welding. Since ultrasonic welding requires a custom mold for the welded object, the complexity of the shape of the welded object limits ultrasonic welding. Ultrasonic metal welding also has limitations. Generally, only metal plates and metal wires can be welded; ultrasonic plastic welding can generally only weld most thermoplastic plastics.


Ultrasonic welding has been widely used since its development, but for different materials, we need to choose the most appropriate welding method. When it is necessary to weld metal wires and metal plates, ABS, PP, PE, PVC, PPS, PC and other thermoplastics, ultrasonic welding is a better solution than traditional welding.KNMTECH has been deeply involved in the field of ultrasonic welding for 15 years. If you have needs for ultrasonic welding, we can provide you with the most complete pre-sales and after-sales services to help you improve your competitiveness.

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