Since the early 1980s, ultrasonics has been used for wire splicing and to weld wires to metal connectors and terminals. Photo courtesy Emerson, showing Branson Ultrasonics Metal Welding technology Ultrasonic welding effectively splices stranded (top) and tinned wire. Photo courtesy Sonobond Ultrasonics Inc. The SPG 2600 welder ultrasonically welds wire bundles of up to 20 square millimeters to a single terminal. Photo courtesy Sonobond Ultrasonics Inc. When the average person opens up a refrigerator and grabs a too-warm soda can or bottle, his initial reaction is one of disappointment. But, if that person is an assembler of harnesses for this type of appliance, his initial thought is: Check the evaporator fan wiring harness. While inspecting it for wear and damage, he’ll also learn whether the wires were welded or soldered to connectors, and how well either process was performed. More than likely, he’ll see that the wires are ultrasonically welded. Harness makers that serve the white goods market increasingly prefer this technology because it produces reliable connections with high conductivity. This is not to say that all such harness makers have made the switch to ultrasonic w...