2042 One Thick + One Thin Wire Harness Welding
Ultrasonic wire harness welding demonstration for copper / aluminum wire bundles and terminals.
Technical Specifications
- Model
- 2042
- Splice type
- thick + thin
- Frequency
- 20 kHz
- Materials
- copper / aluminium
- Air cylinder
- built-in
- Application
- mismatched wire splices
Why this process
- Handles mismatched cross-sections in one joint.
- Energy and clamp force are set independently.
- No solder to fill the size gap.
- Low heat protects the thinner wire's insulation.
Typical applications
Mismatched harness splices · power-to-tail wire joints · repair splices · transition between cable gauges.
FAQs
Can different wire sizes be welded together?
Yes — that is the point of this configuration; energy and clamping force are tuned so the thick wire consolidates without crushing the thin one.
Why not just crimp?
A crimp on mismatched sizes often relies on the thick wire; a weld consolidates both into one metal mass.
Is a filler needed?
No — the metals are joined directly, with no filler to bridge the size difference.
Full machine details → 2042 small wire harness welding machine