Ultrasonic termination of aluminium conductors

Task

An aluminium cable needs to be welded onto a two-part terminal. To begin with, the aluminium terminal needs to be welded to the nickel-plated copper terminal. After that, the weld point has to be sealed in a special injection moulding process. Then the second weld is produced: the aluminium cable is welded to the aluminium terminal. 

Solution

Both welds were produced in sequence using an MT8000 PowerWheel ® system with a 10 kW output. 

Configuration advantages

With its high weld output and specialist technology, PowerWheel ® technology is the only solution to this application. The weld is able to withstand even the highest loads. This technology reliably prevents contact erosion between the aluminium and the copper in the terminal. The process has been approved for use in the automotive industry.






Terminal with double weld and insulation