Complex Vibration Welding Tip Research Articles

Welding Characteristics of Aluminum and Copper Plate Specimens Welded by a 19 kHz Complex Vibration Ultrasonic Seam Welding System

The welding characteristics of aluminum and copper plate specimens welded using a 19 kHz ultrasonic welding system with a complex-vibration welding tip were studied. The welding tip part vibrates in an elliptical or circular locus. The seam welding system uses a rotating circular disk welding tip and a shifting stage for continuous welding of the metal sheets. Using the complex-vibration system, metal plates of various thicknesses can be welded continuously at multiple positions with large and uniform welded areas and large weld strengths independently of the welding position and direction. The required complex-vibration amplitude is less than one-half of that of a conventional linear-vibration system. Aluminum-aluminum, aluminum-copper and copper-copper plate specimens were welded with weld strengths almost equal to the specimen strength.

Complex vibration ultrasonic welding systems with large area welding tips

Vibration and welding characteristics of complex vibration ultrasonic welding systems of 27 and 40 kHz were studied. Complex vibration systems, which have elliptical to circular or rectangular to square locus, are effective for ultrasonic welding of various specimens including the same and different metal specimens, and for direct welding of semiconductor tips and packaging of various electronic devices without solder. The complex vibration systems consist of a one-dimensional longitudinal–torsional vibration converter with slitted part, a stepped horn and a longitudinal vibration transducer as a driving source. The complex vibration welding tips of 27 and 40 kHz have enough area of 6–8 mm square for various welding specimens. Aluminum plate specimens of 0.3–1.0 mm thickness were successfully joined with weld strengths almost equal to aluminum specimen strength, and independent to the specimen direction. Required vibration amplitude of 40 kHz is smaller than that of 27 kHz.

Temperature Rise and Welding Characteristics of Ultrasonic Wire Bonding Using 190 kHz Linear, Circular and Square Vibration Loci and 600 kHz Linear Vibration Locus Welding Tips

Welding characteristics of ultrasonic wire bonding using 190 kHz linear, circular and square vibration loci and a 600 kHz linear vibration locus are studied. High-frequency systems at 90–780 kHz have been shown to be significantly effective in comparison to a conventional system at 60 kHz. Aluminum wire welding specimens 0.1 mm in diameter have been successfully joined. Temperature increases at welding parts are measured from the thermoelectromotive force between the aluminum wire and copper plate specimens, and deformation at welded parts of wire specimens are measured using a digital height gage. Complex vibration welding tips at 190 kHz, which vibrate in elliptical to circular or rectangular to square shapes at either the same or different frequencies, are effective in joining welding specimens successfully in shorter welding times, under smaller vibration amplitudes and over wider good welding areas. A high-frequency 600 kHz system with a linear vibration locus is also effective for successful wire bonding. Both the temperature increase and wire deformation correlate well with the weld strength.

Welding characteristics and temperature rise of high frequency and complex vibration ultrasonic wire bonding

Abstract Welding characteristics of 190 kHz ultrasonic wire bonding systems with linear, square and circular vibration loci are studied. High-frequency systems of 90 ~ 780 kHz were shown to be significantly effective compared with conventional frequency systems. The required vibration amplitude of high frequency becomes very small, i.e 0.04 μm (peak-to-zero value) at 780 kHz which is 1 30 that of 60 kHz [1–3]. Welding wire aluminum specimens 0.1 mm in diameter are joined successfully. The temperature rise at welding part is measured by thermoelectromotive force between aluminum wire and copper plate specimens, and deformation of wire specimens is measured by a height gage. Complex vibration welding tips of 190 kHz which vibrate in elliptical to circular or rectangular to square at the same or different frequencies are shown to be effective in joining welding specimens successfully in a shorter welding time and under smaller vibration amplitude, with a wider good welding domain. Temperature rise and wire deformation have a good correlation with weld strength obtained. With a high frequency longitudinal vibration system, it is very difficult to install a ceramic capillary at its tip because the dimensions of such high frequency systems as 330, 600 or 780 kHz become too small. For installing a ceramic capillary in the high frequency system, longitudinal to complex transverse vibration systems of 160 ~ 575 kHz are proposed and the vibration characteristics of the system and a ceramic capillary are measured. The capillary 1.5875 mm in diameter and 6.5 mm in projection length has one transverse vibration node along its length at 160 kHz and two vibration nodes at 515 kHz.

Welding characteristics of ultrasonic plastic welding using two-vibration-system of 90 kHz and 27 or 20 kHz and complex vibration systems

To improve welding characteristics of ultrasonic plastic welding, a 90 kHz two-vibration-system, which can weld plastic sheets under one-third velocity amplitude compared with that of 27 kHz systems, is effective. However, this system cannot weld large specimens successfully because high frequency vibration stress cannot be transmitted uniformly through the large specimens due to the stress relaxation effect by the small vibration displacement of the high frequency welding tip. The ultrasonic welding systems using the combinations of (1) a high frequency 90 kHz longitudinal vibration system with small displacement amplitude and a low frequency 27 kHz longitudinal vibration system with large displacement amplitude (not velocity amplitude), (2) a 90 kHz longitudinal system and a 20 kHz torsional vibration system with large displacement, and (3) the complex vibration welding system using 27 kHz complex vibration welding tips vibrating in elliptical to circular locus are studied. The welding specimens used are soft (polyvinyl chloride: shear vibration loss is large) and hard (polypropylene) sheet materials, and both specimens were welded successfully with smaller velocity amplitude than that of the conventional welding method, similarly in both cases where (1) parallel and (2) normal direction vibration systems are driven simultaneously. The complex vibration welding systems of 27 kHz which has elliptical and circular vibration loci were revealed also effective for plastic welding.

New methods of ultrasonic welding of metal and plastic materials

New ultrasonic welding methods of metal and plastic materials have been proposed by the author and have shown their effectiveness. For welding of thick and large metal specimens, (1) an ultrasonic butt welding method of joining thick metal specimens end to end is proposed. Large capacity vibration sources and solid-state power amplifiers of 50, 100 kW have been developed. (2) The welding method of using two vibration systems crossed at a right angle is effective, and 10 mm thick aluminum plates have been joined successfully. For medium size metal welding specimens, (3) complex vibration welding tips have been shown to be very effective, and one-dimensional complex vibration systems are developed to simplify the systems. For welding of small metal specimens, (4) higher vibration frequency, and complex vibration wire bonding systems are proposed and it is shown that they are significantly effective. Bonding systems of 60 to 600 kHz have been designed. For welding of plastic materials, (5) high frequency and two-vibration-system welding methods are effective.

Ultrasonic wire bonding using high frequency 330, 600 kHz and complex vibration 190 kHz welding systems

Welding characteristics of ultrasonic wire bonding using a same frequency complex vibration welding system of 190 kHz and high frequency linear vibration welding tips of 330 and 600 kHz are studied. The welding equipment used is (1) same vibration frequency complex vibration wire bonding systems of 190 kHz and (2) high frequency linear vibration wire bonding systems of 330 and 600 kHz. Complex vibration welding tip locus shapes are controlled from linear to elliptical, and circular, by regulating the driving vibration systems. The required vibration velocity of the complex vibration system is about half to one third compared with linear vibration systems. The required vibration velocity of the high-frequency bonding system of 600 kHz decreases to about one-fifth that of the 60 kHz conventional bonding system. Using high frequency and complex vibration systems, the weld strength becomes independent of the direction between welding tip vibration and wire length.

Welding Characteristics of Ultrasonic Wire Bonding Using High-Frequency Vibration Systems

Welding characteristics of ultrasonic wire bonding using 60 kHz, 90 kHz and 120 kHz complex vibration as well as 190 kHz linear vibration welding systems are studied. The locus shapes of the complex vibration welding tip are controlled from linear to elliptical or circular. Aluminum wire specimens of 0.1 mm diameter are welded successfully using complex and high-frequency welding equipment. The required vibration amplitudes of these complex vibration systems are about one-half to one-third and required weld time is shorter than those of a conventional system of linear vibration. The required vibration velocity of a high-frequency system is lower than that of a low-frequency system. The deformations of the welded specimens under adequate welding conditions are almost the same, even if the welding tip vibration locus is altered from linear to elliptical or circular, or the vibration frequency used is changed from 60 kHz to 190 kHz in the case where the same wire specimens are used. Using these methods, the weld strength of wire bonding becomes independent of the difference in the directions of the welding tip vibration and wire length.

Welding Characteristics of Ultrasonic Wire Bonding Using High-Frequency Vibration Systems

Welding characteristics of ultrasonic wire bonding using 60 kHz and 90 kHz complex vibration as well as 120 kHz linear vibration welding systems are studied. The locus shapes of the complex vibration welding tip are controlled from linear to elliptical or circular. Aluminum wire specimens of 0.1 mm diameter are welded successfully using the welding equipment. The required vibration amplitudes of these complex vibration systems are about one-half to one-third and required weld time is shorter than those for a conventional system of linear vibration. The required vibration velocity of a higher-frequency system is smaller than that of a lower-frequency system.

Ultrasonic Welding of Thin Metal Plates Using a Complex Vibration Welding Tip

Ultrasonic welding of thin metal plates using a complex vibration welding tip is studied. The welding tip vibration locus shape is changed from linear, elliptical, to circular using a pair of the same frequency 27 kHz complex vibration systems. Aluminum and copper plate specimens of 0.5 to 1.0 mm thickness were welded successfully using this welding system. Required vibration amplitude is about half compare to a conventional system. Weld strength and weld area obtain by this system are larger, and welded area becomes more concentrated than these by a conventional system. The weld strength also was independent of specimen direction.

Detection of welding condition and welding characteristics of ultrasonic wire bonding using a complex vibration welding tip : IEEE 1989 Ultrasonics Symposium Montreal, Quebec (Canada), 3–6 Oct. 1989 Vol. 2, pp. 1103–1106. Edited by B.R. McAvoy. IEEE (1989)

Detection of welding condition and welding characteristics of ultrasonic wire bonding using a complex vibration welding tip : IEEE 1989 Ultrasonics Symposium Montreal, Quebec (Canada), 3–6 Oct. 1989 Vol. 2, pp. 1103–1106. Edited by B.R. McAvoy. IEEE (1989)

Welding Characteristics of Thin Copper Wire Using Complex Vibration Ultrasonic Wire Bonding Systems

Welding characteristics of thin copper wire using complex vibration ultrasonic wire bonding are studied. The welding systems used have a complex transverse vibration welding tip which is driven by two longitudinal vibration systems crossed at a right angle. Welding tip vibration locus shape is controlled by regulating these vibration systems. Welding specimens used are 0.025 mm diameter copper wire and 1.0 mm thick copper plate. These specimens are welded successfully with smaller vibration amplitude and shorter weld time than a conventional welding system. Weld strength is independent of specimen wire direction.

Welding Characteristics of Ultrasonic Wire Bonding Using the Same or a Different Frequency Complex Vibration Welding Tips

Welding characteristics of complex vibration ultrasonic wire bonding are studied. The welding systems used have a complex transverse vibration welding tip which is driven by two longitudinal vibration systems. Welding tip vibration locus shape is controlled by regulating the vibration amplitudes and phase difference between two vibration systems. Welding specimens used are 0.1 mm diameter aluminum wire and 1.0 mm thick copper plate. These specimens are welded successfully with smaller vibration amplitude and shorter weld time than a conventional welding system. Weld strength is independent of specimen wire direction.

Studies on Ultrasonic Wire Bonding Using the Same or a Different Frequency Complex Vibration Welding Tip

Ultrasonic wire bonding using a complex vibration tip is proposed and studied. The complex vibration welding tips designed consist of a transverse vibration rod vibrating in a perpendicular direction, and driven by (1) different (40 kHz and 60 kHz) or (2) the same vibration frequency (60 kHz) longitudinal vibration systems. Welding tip vibration locus and direction are controlled by regulating these vibration systems. Thin aluminum wire and copper plate specimens are welded successfully by these equipments. The weld strength also is independent of the direction of wire length with this method.