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What problems will appear in products welded by ultrasonic metal spot welders after the welding horn wears?
Nov 10,2026
When ultrasonic metal spot welders weld products such as copper braided wires and copper terminals, wear, shallower tooth profiles, and material adhesion on the end face of the welding horn after long-term use will change vibration transmission, pressure, and fit status.
I. Insufficient weld bonding strength
1. Wear and shallower tooth profiles of the welding horn weaken the biting and friction effect with the wire, interface bonding is insufficient, and weld strength decreases.
2. After wear, vibration energy transmission efficiency decreases, the copper wires are not fully welded to each other or to the terminal, and false welds appear.
3. Weld pull-out force is insufficient, pull tests fluctuate greatly, and some products scatter with a gentle pull.
II. Increased loose wires and broken wires
1. After welding horn wear, pressure distribution is uneven, local copper wires are subjected to excessive force and are easily crushed or broken by vibration.
2. Tooth profile wear causes unstable wire fixing, and under ultrasonic vibration the copper wires easily slide outward, spread, and lift.
3. The surface of severely worn welding horns is rough and easily catches and pulls copper wires, causing broken wires.
III. High weld resistance and heating hazards
1. Insufficiently bonded welds have increased contact resistance and higher temperature rise after energization.
2. Weld resistance consistency is poor, resistance fluctuates greatly among products in the same batch, affecting subsequent use reliability.
3. Welds with high resistance are prone to heating and oxidation under long-term energization or vibration environments, accelerating failure.
IV. Poor weld appearance and forming
1. After welding horn wear, indentation depth and shape are inconsistent, and weld appearance consistency is poor.
2. Material and copper chip adhesion on the end face are imprinted on the workpiece surface, forming pits, pockmarks, and stains.
3. Weld surfaces are black and rough, forming is not full, and the appearance inspection failure rate increases.
V. Accelerated wear of welding horn and equipment
1. After wear, the force on the welding horn is uneven, local wear accelerates, forming a vicious cycle and increasing replacement frequency.
2. After material and copper chip adhesion, vibration transmission deteriorates, the equipment requires higher energy output, and the load increases.
3. Worn welding horns easily damage the anvil and tooling, increasing maintenance costs.
VI. Decline in batch production consistency
1. The degree of welding horn wear changes with production time, product quality fluctuates with time, and batch consistency is poor.
2. Welding horns on multiple machines have different wear states, and product differences are obvious under the same parameters.
3. Products welded by worn welding horns are prone to loosening and wire breakage in subsequent assembly or use.
Wuxi Haifei Intelligent Equipment Co., Ltd. official website: https://www.haifeiwelder.com/
Wuxi Haifei Intelligent Equipment Co., Ltd. has been dedicated to the research and production of ultrasonic metal spot welding machines for 17 years. The company has passed the ISO9001 quality management system certification, the national 3C certification and the CE certification. It is a national high-tech enterprise, a Specialized, Refined, Distinctive and Innovative enterprise of Jiangsu Province, a Specialized, Refined, Distinctive and Innovative enterprise of Wuxi City, and a Gazelle enterprise of the Southern Jiangsu National Independent Innovation Demonstration Zone. If you are interested in our ultrasonic metal spot welding machines, please contact us: liuyiyu@jshaifei.com
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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