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• Abstract: Ultrasonic consolidation (UC) is a solid freeform fabrication technique developed for the manufacture of metal parts. The mechanisms by which bonds are formed, during the UC process, are based on a combination of the surface effect and the volume effect. Based on the outcomes of peel tests and microstructural analysis, this paper will consider the influence of these two phenomena on the weld strength of specimens. A model is presented to describe how calculations for weld strength may be derived on the basis of the theory of surface and volume effects. Through the application of the model, it was possible to demonstrate that the weld strength may be 7 per cent greater than the tensile strength of the base metal. The identification of the phenomena and the development of a model for weld strength have led to the modification and production of an enhanced test procedure which is described in this paper.