Ultrasonic Resistance Spot Welding Process and Apparatus

An improvement to ultrasonic and resistance spot welding

The Need

Ultrasonic welding is widely used in the electronics industry to weld together wiring in delicate circuits and on microcircuits. It is also used in the automotive industry, medical industry, and packaging industry, often to weld dissimilar materials or plastics. The major advantages in ultrasonic welding are that it is a fast welding speed technique that also exhibits high energy efficiency. However, it is currently restricted to softer materials and thin work pieces. There is a need for an improved welding process that can weld dissimilar materials effectively, but can also be used on stronger materials, thicker workpieces.

The Technology

Researchers at The Ohio State University, led by Professor Xun Liu, have developed an improvement to the ultrasonic welding process that allows it to be used for stronger and thicker materials. The technology utilizes techniques of resistance spot welding while still allowing dissimilar materials to be welded together effectively. This technology greatly expands the capability of ultrasonic welding.

Commercial Applications

  • Automotive Manufacturing
  • Aerospace Manufacturing
  • Packaging
  • Battery Production


  • Maintains the speed of ultrasonic welding
  • High energy efficiency welding technique
  • Effective welding of dissimilar materials
  • Ability to weld together thicker materials than traditional ultrasonic welding techniques
  • Ability to weld stronger materials than traditional ultrasonic welding techniques
  • Can be easily adapted to current welding systems that are commonly used in industry

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