An improved ultrasonic surgical instrument is disclosed having a design that extends horn or tip life and minimizes instrument breakage and disintegration during use. The instrument comprises an ultrasonic tip having a distal working end and a metal sheath around the tip; the tip further having projections located in the vicinity of nodal points near the tip working end, said tip radially extending from the tip towards the sheath so as to provide the tip with radial inward support. The instrument can further comprise said tip with a substantially flat or convex end and said sheath with an inwardly projecting portion located distally of said tip projection and extending sufficiently radially inward so as to capture the tip with its projection should a tip break occur.