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Over-Welding Defects Caused by Excessive Welding Time on Ultrasonic Metal Welders
Jul 17,2026
Ultrasonic metal welding is a core joining process for new energy harnesses, extensively used in new energy vehicles and energy storage equipment. Excessively long welding time leads to over-intake of ultrasonic energy, breaks welding balance and triggers multiple over-welding failures, detailed as follows.
I Core Causes of Over-Welding
1.Continuous accumulation of frictional heat resulting in excessive temperature.
2.Long-term high-frequency vibration causing layered damage of materials.
II Main Failures Induced by Overlong Welding Time
1 Reduced Mechanical Strength & Easy Fracture
Over-fused nuggets develop coarse grains and internal cracks; harness filaments soften and break, joints become brittle and crack under slight vibration or bending. This disrupts normal equipment operation and brings safety risks, together with high rework costs.
2 Deteriorated Electrical Conductivity & Severe Overheating
Oxide layers and pinholes form inside joints, increasing unstable resistance. Connectors heat drastically after electrification and accelerate insulation aging; superficial conduction with internal broken wires may occur.
3 Irreparable Damage to Harness & Terminals
Harness filaments melt and stick together, insulation cracks; terminals deform and burn. Both parts are scrapped with no repair possibility.
4 Accelerated Equipment Wear & Shortened Service Life
Horns suffer faster wear and oxidation; transducers and boosters run under overload with heavier load on cooling systems, raising breakdown risks.
5 Hidden False Welds Hard to Detect
Smooth surface with no obvious flaws, yet no effective metallurgical bonding inside — only superficial adhesion with fluctuating resistance, prone to detachment after long service.
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Wuxi HAIFEI Intelligent Equipment Co., Ltd.
Wuxi HAIFEI Welding Equipment Co., Ltd.
Add: 28 Shuiyun Road, Yuecheng, Jiangyin, Jiangsu Province, China. (Postal Code: 214404)
Mobile: +86 18915302352
Email: wushijie@jshaifei.com