An ultrasonic battery tab welding machine joins thin copper, aluminum and nickel foils and tabs in battery cells, modules and packs — the standard joining process for EV cells, energy-storage systems and BMS connections. Sinceresonics supplies ultrasonic metal welders configured for tab welding, with the parameter recipes and weld-check routines that battery production demands.
Where Ultrasonic Tab Welding Is Used
- Cell manufacturing — foil-to-tab and tab-to-terminal welding on cylindrical, pouch and prismatic cells
- Module and pack assembly — busbar-to-tab interconnects, stacking multiple foils in one weld
- BMS and wiring — wire harness splicing and terminal-to-wire joints
- Spot welding for car batteries — nickel strip and tab spot welds for pack repairs and small packs
Weldable Materials and Stacks
| Material | Typical Stack | Notes |
|---|---|---|
| Aluminum foil / tab | 10 – 400 µm foil, 1 – 8 layers | Excellent ultrasonic response; watch for sticking on pure Al |
| Copper foil / tab | 8 – 200 µm foil, 1 – 8 layers | Higher power than Al; standard for anode tabs |
| Nickel strip | 0.1 – 0.3 mm strip | Common in pack repair and small packs |
| Dissimilar joints | Al + Cu, Cu + Ni | Ultrasonic avoids the brittle intermetallics that fusion welding creates |
Machine Selection
Tab welding runs on our direct-press servo ultrasonic metal welder: servo-controlled force and depth, energy/depth/pressure monitoring per weld, and tooling matched to the foil stack. For continuous seams and enclosure work, see the non-ferrous metal welder. Both share the same transducer platform as our 20 kHz welding transducers.
| Parameter | Specification |
|---|---|
| Frequency | 20 kHz (15 kHz for heavy busbar stacks) |
| Power | 2,000 – 5,000 W |
| Force range | 200 – 2,000 N, servo-controlled |
| Weld mode | Energy / time / depth, with monitoring |
| Process data | Energy, power curve, depth per weld — I/O or fieldbus |
Weld Quality and How We Verify It
- Pull / peel strength — sample welds pulled to failure against a target tensile value per foil stack
- Weld penetration and nugget — cross-section check for bond area without foil tearing
- Electrical resistance — micro-ohm measurement per weld recipe
For the standard landscape (ISO, IEC and customer specs), read our ultrasonic metal welding standard for battery tab welding. Application-level overviews: battery market page and non-ferrous metal welding machine.
FAQ
How many foil layers can be welded at once?
Commonly 2–8 layers of 10–20 µm foil, or a foil stack to a thicker tab. Send us your stack-up — trial welds are free and the recipe ships with the machine.
Do you support anvil dressing and replacement?
Yes. Anvils and sonotrodes are consumables; we supply spares matched to your machine and refurbish worn tooling — see horn and sonotrode services.
Can the machine integrate into our line?
Yes — weld modules for special equipment and production lines are a standard offering, with fieldbus integration.
Get a Tab Welding Quotation
Send your foil stack-up and target weld strength — we’ll trial-weld your samples and return a machine configuration with the measured results. Email jackm@mcsonic.com or call +86 189 3970 6772.