Wire Bonding Ultrasonic Metal Welding Machine

Wire Bonding Ultrasonic Metal Welding Machine

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In Wire Bonding Ultrasonic Metal Welding Machine, the word “welding” evokes a particular image, the exposed flame of torch and red hot molten metal, metal parts are heated to a liquid state to joint them to one another, for small scales and electrical products, metal wire, metal sheets, metal strips, metal foils are not a viable bonding method, ultrasonic welding allows a bond to from between metals without requiring the metal to leave the solid state, so-called metal atom disperse and interchange applied proper pressure, ultrasonic vibration scrubbing only cause the local position heated and quick drop down, which did not reach the metal melting point in molecular scales connection

Wire bonding ultrasonic welding uses friction created by high-frequency vibration to create a bond without requiring metal wires to become molten

Wire Bonding Ultrasonic Metal Welding is a solid state process that creates metallurgic bonds through ultrasonic vibration friction, the benefit of creating bonds without melting the metal wire is that no inter-metallic compounds or particulates are created, the bonding structure are build in metal wire itself, this also eliminates the risk of corrosion

Wire Bonding Ultrasonic Metal Welding Machine not only can be used to bond metal wires, but also can be used to bond a wide variety of soft, conductive non-ferrous metals ranging from copper, aluminum, and nickel, to lithium, brass, silver and gold, unlike ultrasonic plastic welding, ultrasonic metal welding allows dissimilar metals to be successfully bonded, this ability makes ultrasonic metal welding this ideal bonding process for applications involving power storage devices, wire harnesses and electronic tiny assembles. Electrical breakers, and switches, consumer electronics and cell phones, and even implantable medical devices

Electric bus, vehicles, motor has power storage battery pack, the negative and positive terminals and power core of metal foil layers are all boned by ultrasonic metal welding machine, which is able to bond very thin metal foils, down to five micron and have the capability to bond these metal foils in up to 100 layers, enabling the assembly of high-power lithium batteries and super capacitors, ultrasonic metal welding machine also have big power to weld thick metal wire in up to 20mm diameter

Another difference between ultrasonic welding of plastic and metal is the application of the amplitude, the amplitude is applied to the upper component in a vertical direction in ultrasonic plastic welding, whereas the amplitude is applied to a side laying component in a lateral motion for metal materials

In comparison to other soldering and crimping, ultrasonic metal welding doesn’t require added materials or consumables to create a bond, the process offers repeatable results and a higher level of control that other bonding techniques, because, there are many variables involved in the ultrasonic metal process: amplitude, frequency, pressure and tooling, time is sometimes needed to develop weld parameters and tooling that is ideally suited to the specifics of particular application, in wire bonding ultrasonic metal welding process is atom disperse and interchange, can max reduce the electric resistance up to zero

While the process is highly repeatable and controllable, ultrasonic metal welding requires training and testing to produce accurate results, if the technique is not done properly, the bonded metal wire can become embrittled, ultrasonic metal welding also requires extensive testing such as pull, peel and resistance destruction testing, to achieve accurate, repeatable bonds, the design of the tooling itself plays an integral part in the success of the bond, as usually, the key to success in ultrasonic metal welding applications involves the design, detail, and implementation of the welding tools, the horn, also called ultrasonic sonotrode, the half of the tooling that transmits the ultrasonic energy through one of the parts to the weld zone between the parts, must have a proper combination of base anvil or pneumatic clamping device. Shape, surface texture and knurl patterns to efficiently delivery that energy

Choosing the appropriate ultrasonic metal welding for the task is also essential to choose the right frequency for the metal wire and other metal product, company: keepleader offers a range of ultrasonic metal welding and services to meet ever-changing industry demands, including automation integration, ultrasonic metal welding can be used to bond metals in a variety applications, the popular industrial field is metal wire, harness, and storage power batteries bonding

Frequency asked question below for reference

01: How does ultrasonic metal welding work?

Parts to be joined are held together between the ultrasonic horn and anvil or pneumatic clamping fixture, they experience ultrasonic vibration of 20 to 40khz, depending upon application, vibration of the horn causes the parts to scrub together (in shear) that removes surface contaminants to expose bare metal areas, the metal ‘s atomic structures then co-mingle to create a strong surface molecular, solid-stage bond that is clean and has low electrical resistance, these properties together make the ultrasonic metal welding ideal for electronic application, wire harness, battery anode connection and more

02: What strength is expected from metal joined ultrasonically?

Usually, the bond created is as strong or stronger that the parent metal, especially for stranded wire and braided wire, the wire is mingled together, the foil layers bonding also have the same performance in storage power batteries

03: What metal can be joined ultrasonically?

Generally, non-ferrous metals: aluminum, sliver, gold, copper, brass, nickel and alloys of these metals, application include battery foil/tab/connecting sheet/strip welding, wire splicing, wire termination, spot welding, seam welding and copper tube end sealing for refrigeration industry

04: What about steel components for ultrasonic metal welding?

Welding to iron, steel and stainless steel is not recommended because they are harder that non-ferrous metals, the surface structure are too dense and don not allow the the transfer of materials for consistent bonding, the parameters required would be more aggressive with heat build-up, resulting in increasing tooling wear, while bonding many occur, consistent weld strength is difficult to achieve

05: What about dissimilar metals such as aluminum to copper?

Ultrasonic metal welding works well for dissimilar metals because the process is the same whether the materials are similar or not, examples including battery nickel, copper tab, foil welding, silver-pate or copper stranded wire to nickel-plated copper or brass terminals, copper pads to a aluminum heat sinks, and precious metal contacts to contact arms, among others

06: What about plated metals?

It depends upon the plating, the tin plating inhibits the bonding process, action more like a lubricant, the tin heats up and many actually reflow, the metal parts slide over each other rather scrubbing against each each, heat builds up which has a negative effect, especially on wire strands, as they become brittle and usually break, silver and gold plating is different, these are more compatible because they seem to move away from the weld area or are able to be scrubbed through to get to the base metal, application with these plating include stranded wire spicing, and tipping,wire termination to plated terminals or lead frames

07: what are weld size and metal thickness restrictions?

6mm square for 40khz and up to 12mm for 20khz, the metal can be any thickness on the anvil side of the weld as long as it can be held stationary either on the anvil or by pneumatic clamping. on the horn side, metal can be up to 3mm, provided sufficient power is available from the controller.

08: What amount of tool wear is expected?

This depends upon the melt being joined, harder metals that require more aggressive parameter result in higher tool wear versus softer metals that require less aggressive parameter settings

09: Can tooling be reworked for extended use?

Many times a horn or replaceable tip can be reworked (re-knurled) one time, more if the rework allows the tool to remain to print or weight specifications, tick anvils may be re-knurled as long as they can still be clamped in position in the tool support or fixture and hold the part as required

10: Can the same tooling be used for different applications?

Most tooling is custom made for specific applications, specially the fixture, the knurl patterns on the horn and anvil are specified according to metal thickness and weld area requirements as well as part configurations, some tooling combinations may be used for situation, other that the original application, but may need modification.

How much training is needed for the operation of new machine?

Wire Bonding Ultrasonic Metal Welding Machine is very easy to operate and do not require any certification, keepleader tech team provides training when installing the machine and application, training includes operation of the controls, how and when to change tooling, parameter settings and place multiple application setups in the preset menu if needed

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