Emerson Introduces Branson GMX-20MA Ultrasonic Spot Welder for Non-Ferrous Metals

Emerson’s Branson GMX-20MA ultrasonic spot welder is targeted to the automotive industry and the power supply industry, as it is suitable for welding automotive wiring, connectors, bus bars, and battery tabs.

 

Ultrasonic Welding

Ultrasonic welding uses a combination of pressure and high-speed vibrations to heat metal parts and weld them together. First, the pieces are clamped under high pressure to ensure contact. Then, an ultrasonic acoustic wave is transmitted into one part of the clamp, forcing the metal underneath to vibrate. With each passing pulse, the two metal pieces bump into each other, generating heat. 

 

The ultrasonic welding process converts electrical energy into mechanical vibrations causing the metals to join. Image courtesy of Emerson.

 

In ultrasonic welding, the metal does not melt. Instead, the repeated vibrations remove the protective layer of oxide that forms on the metal’s surface. As a bonus, the vibrations “scrub” the surfaces, meaning surface precleaning is often unnecessary.

As the metal pieces rub into each other, they begin to heat up due to frictional losses. The high temperature is the measurable quantity related to atomic motion—the higher the temperature, the more atomic motion. Without the protective oxide layer in place, atoms from one metal workpiece begin to bond with those from the other workpiece, forming a strongly-attached assembly called a solid-state weld.

 

Branson GMX-20MA Spot Welder’s Key Features

While many spot welders are on the market, several key features give the Branson GMX-20MA some distinct advantages. One of the most challenging parts of perfecting an ultrasonic weld on metals is ensuring that the pressure is correct and evenly applied. The GMX-20MA has a digital load cell to ensure that the load applied is predictable and repeatable. 

Furthermore, it has a dual set of linear bearings to ensure that the load is applied evenly across the workpiece compared to a single set of linear bearings found on competing ultrasonic spot welders. When the load is applied, the ram’s position is measured using a linear encoder, providing another mechanism to minimize variability between welded assemblies. 

The dual set of bearings keeps the pneumatic ram at a consistent and controllable pressure during the weld, improving every weld’s quality.

Emerson's Branson GMX-20MA ultrasonic metal spot welder. Image courtesy of Emerson.

 

All of these features lead to a strong, repeatable weld. According to Emerson’s metal welding division, the company believes that the Branson GMX-20MA is the strongest ultrasonic metal welder on the market due to its precise actuator. The company hopes to deliver the highest repeatability and stability for metal welding in several conditions.

 

Touchscreen Controller

To run the Branson GMX-20MA, there is a user-friendly touchscreen controller. From this interface, the user can perform welding operations in several modes, specified by time, energy, peak power, and distance. All data collected during the weld is stored in an archival manner, such that any issues that arise can be quickly diagnosed and repaired. The controller has a built-in Visual Quality Screen (VQS) for catching quality control issues early in processing.

Overall, the Emerson Branson GMX-20MA adds repeatability and stability to any industry that will use ultrasonic welding in their processes, such as automotive, electronics, and medical.