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In Ultrasonic Metal Spot Welding of Aluminum Plate and Nickel Sheet, the Aluminum Plate Collapses and Deforms. What to Do?

Oct 27,2026

In ultrasonic metal spot welding of aluminum plate and nickel sheet, indentation, collapse, and thickness reduction easily occur, and in severe cases it welds through.

I Welding Process Parameters

1.Do not set the welding pressure too high. Pressure is the main factor causing aluminum-plate collapse. Reduce the pressure appropriately to avoid the welding head instantly impacting and crushing the aluminum plate, and also check whether the pressure output is stable.

2.Reasonably control the amplitude. If the amplitude is too high, frictional heating is intense, and the aluminum plate softens quickly and is easily squeezed to collapse.

3.Control the welding duration and holding time, reduce continuous energy input, and avoid the aluminum plate being softened and pressed for a long time.

II Welding Head Maintenance

1.Keep the welding head flat. If wear, pits, or chipping appear, dress or replace it in time.

2.Ensure the welding head is centered and parallel to prevent one-sided force from causing one-side collapse.

III Tooling Positioning and Support Optimization

1.Add a hard support block directly below the weld spot. Do not weld the aluminum plate in a suspended state; the suspended position easily sinks under pressure.

2.The clamping force of the fixture should be moderate. Clamping too tightly makes the aluminum plate deform in advance, and the deformation worsens further after welding.

3.Fix the positions of the aluminum plate and nickel sheet to prevent the workpiece from sliding and misaligning during welding.

4.Ensure the workpiece fits tightly before welding. When the gap is large, the vibration rubbing squeezes and damages the aluminum plate.

IV Workpiece Incoming-Material Control

1.Give priority to selecting suitable sheets, and pick out warped workpieces with creases in advance.

2.Clean oil and oxide scale on the aluminum plate and nickel sheet surfaces. Impurities cause slipping and abnormal heating, aggravating deformation.

Wuxi Haifei Intelligent Equipment Co., Ltd. https://www.haifeiwelder.com/

Wuxi Haifei Intelligent Equipment Co., Ltd. has been focusing on the R&D and production of ultrasonic equipment for 17 years. The company has obtained ISO9001 Quality Management System Certification, China Compulsory Certification (3C) and CE Certification. It is a National High‑tech Enterprise, a Specialized, Refined, Differential and Innovative Enterprise of Jiangsu Province, a Specialized, Refined, Differential and Innovative Enterprise of Wuxi, and a Gazelle Enterprise in the Southern Jiangsu National Self‑Dependent Innovation Demonstration Zone.

Should you be interested in our ultrasonic equipment, please contact us: 400‑0510‑750

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