A method of forming a cooling structure for a heat-dissipating surface includes arranging a heat spreader layer adjacent the heat-dissipating surface, bonding a coldplate directly to the heat spreader layer opposite the heat-dissipating surface, and forming an intermetallic bond between the heat spreader layer and the coldplate. The coldplate is bonded to the heat spreader layer using ultrasonic additive manufacturing.

An ultrasonic welding system for a rechargeable battery for mutually welding and bonding includes: a welding apparatus including an anvil and a horn to perform welding and bonding an electrode tab and an electrode lead extending from an electrode assembly of the rechargeable battery through ultrasonic welding by mutually pressing the electrode tab and the electrode lead supplied between the anvil and the horn; and a supply device moves in a vertical or horizontal direction and supplies the electrode lead between the anvil and the horn.

Apparatus are provided for ultrasonic welding of a workpiece of one or more components. The apparatus includes a horn configured to contact the workpiece and to transmit energy to the workpiece. The horn includes a shank and a tip disposed at an end of the shank facing the workpiece. The tip has a face that has a tip radius forming a curved surface at the face. A knurl is formed on the face across the curved surface.

A bonding tool as the tool for ultrasonic bonding includes a plurality of protrusion portions in a protrusion region at a contact tip portion. The plurality of protrusion portions are equally spaced at a longitudinal direction interval in an X direction as the longitudinal direction of the protrusion region, and an X direction outermost protrusion portion positioned outermost in the X direction is disposed separately from a side edge of the protrusion region in the X direction by a longitudinal direction side edge distance. The plurality of protrusion portions are disposed so that a first disposition condition {0.349EX (the longitudinal direction side edge distance/DX (the longitudinal direction interval)0.510} is satisfied.

Method for establishing a connection between an electrical connecting element for a motor vehicle on-board network and a cable of the motor vehicle on-board network in which the cable (2) is provided with a metallic stranded conductor (4), firstly the metallic stranded conductor is mechanically compacted in such a way that a flat area is formed, whereby during the compacting, a material bond is formed between strands of the stranded conductor (4), and subsequently, the connecting element is connected to the flat region in a material bond.

In an ultrasonic machining apparatus having leaf springs composed of fiber-reinforced plastic, the leaf springs are provided with a reinforcement in the region of a clamping.

Apparatus are provided for ultrasonic welding of a workpiece of one or more components. The apparatus includes a horn configured to contact the workpiece and to transmit energy to the workpiece. The horn includes a shank and a tip disposed at an end of the shank facing the workpiece. The tip has a face that has a tip radius forming a curved surface at the face. A knurl is formed on the face across the curved surface.

A welding method includes: moving a welding head toward a plurality of workpieces, wherein each of the plurality of workpieces includes a polymeric composite, the polymeric composite includes a polymer matrix and a plurality of fibers, and each of the fibers includes a magnetic material; applying a joining pressure to the workpieces with the welding head; applying energy to the plurality of workpieces to melt an interface between the plurality of workpieces, wherein a weld plane is defined at the interface between the plurality of workpieces; and applying a magnetic field to the plurality of workpieces to change an orientation of the plurality of fibers relative to the polymer matrix in the weld area so that the fibers in a weld area are at an angle relative to the weld plane.

An ultrasonic additive manufacturing system may include a base structure, a sonotrode configured to rotate about an axis of rotation, and one or more transducers configured to vibrate the sonotrode. The sonotrode may include a welding surface extending along a circumference of the sonotrode, and the welding surface may have a contoured profile. At least one of the sonotrode and the base structure may be configured to translate relative to the other of the sonotrode and the base structure.

An ultrasonic welding system is provided. The ultrasonic welding system includes a support structure for supporting a workpiece. The ultrasonic welding system also includes a weld head assembly including an ultrasonic converter carrying a sonotrode. The weld head assembly is moveable along a plurality of substantially horizontal axes. The sonotrode is configured to operate during a welding operation at a bond force of between 5-500 kg, and with a sonotrode tip motion amplitude of between 5-150 microns.