Ultrasonic energy has been employed for metal joining for many years. In this process, known as ultrasonic metal welding, different types of metals are fused without the need for external heat or electrical currents flowing through the materials.

This method allows ultrasonic energy to penetrate surface contaminants and form a strong, clean bond, enhancing both the quality and precision of the weld. During welding, one component remains fixed while the other is pressed under a rapidly vibrating horn. This vibration causes the materials to soften into a plastic-like state, enabling their molecules to intermingle and create a solid bond.