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While many engineers remain reluctant to switch from older resistance welding or soldering methods, the auto industry is recognizing the advantages of ultrasonic welding, fast becoming a popular alternative for assembling wire harnesses, especially for lightweight aluminum varieties. The process provides the lowest resistance weld available, allowing for the use of smaller cables, which saves the auto makers money and space. But, warns a new report, ultrasonic welding may not be ideal for all wire processing applications.
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