Abstract
The purpose of this paper is to present an advanced method for welding fine wire to metal sheet, namely laser indirect shock welding (LISW). This process uses silica gel as driver sheet to accelerate the metal sheet toward the wire to obtain metallurgical bonding. A series of experiments were implemented to validate the welding ability of Al sheet/Cu wire and Al sheet/Ag wire. It was found that the use of a driver sheet can maintain high surface quality of the metal sheet. With the increase of laser pulse energy, the bonding area of the sheet/wire increased and the welding interfaces were nearly flat. Energy dispersive spectroscopy (EDS) results show that the intermetallic phases were absent and a short element diffusion layer which would limit the formation of the intermetallic phases emerging at the welding interface. A tensile shear test was used to measure the mechanical strength of the welding joints. The influence of laser pulse energy on the tensile failure modes was investigated, and two failure modes, including interfacial failure and failure through the wire, were observed. The nanoindentation test results indicate that as the distance to the welding interface decreased, the microhardness increased due to the plastic deformation becoming more violent.
Highlights
With the rapid development of the micro-electromechanical and medical instruments industry, joints are often made between components of considerably different geometries and sizes
Al sheet was covered with black paint after after welding since the Al sheet was stuck to black paint with cyanoacrylate adhesive
This is a great superiority for laser indirect shock welding (LISW) compared with laser microwelding and resistance microwelding in the welding of fine wire to metal sheet
Summary
With the rapid development of the micro-electromechanical and medical instruments industry, joints are often made between components of considerably different geometries and sizes. Several different welding methods can be applied to this occasion involving resistance microwelding, wire bonding, and laser microwelding. Friis et al [1] welded 316L stainless steel wire to a block through resistance microwelding and found that current has a significant influence on joint formation, and the softening of materials was induced. 316L stainless steel to Pt wire and investigated the joint breaking force, fracture mode, and interfacial metallurgical phenomena. Mo et al [3] focused on the mechanism of resistance microwelding of insulated copper wire to phosphor bronze sheet. They investigated the effects of the main process parameters and joint microstructure. Shi et al [5] conducted experimental research on laser microwelding of a fine copper wire to an Al pin of an integrated circuit chip
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