Comparison Between Ultrasonic Immersion Welding and Traditional Tin Plating

Introduction:

 

Ultrasonic immersion welding equipment is mainly used for soldering tin on enameled wires and welding materials that are difficult to weld using conventional methods. Compared with traditional welding methods, ultrasonic immersion welding is more environmentally friendly and energy-saving. The ultrasonic vibration and cavitation phenomena during the immersion welding process are prone to the detachment of the oxide layer on the surface of the welded part. At the same time, the high-frequency vibration energy does not melt the solder, which helps the solder to wet the welded part. Because it does not require soldering flux, it saves time and cost for cleaning residual soldering flux, while reducing corrosion to enhance the durability of the welded joint.

 

Common problems with traditional tin plating:

1. Can only tin plated copper and aluminum, with a relatively narrow scope of application.

2. Before tin plating, it is necessary to remove the oxide layer on the metal surface, which is a complex process.

When tin plating, flux must be used, which pollutes the environment and is harmful to human health.

4. Solder cannot penetrate tiny gaps, making it impossible to achieve perfect welding.

5. Flux and flux cleaning processes are required, which are inefficient and expensive.

Advantages of ultrasonic immersion welding:

 

1. Green and environmentally friendly soldering (indium) solution

• It will not emit any harmful chemicals to the environment and human health, and does not require soldering flux or soldering flux cleaning process.
• When soldering (indium), no flux is used, no harmful gases are emitted, no industrial wastewater is generated, and there is no water pollution or air pollution.

2. Achieve perfect soldering (indium)

• When soldering (indium), if flux is used, tiny bubbles will be generated inside the solder (indium), which can lead to quality problems such as cracks over time. However, ultrasonic soldering (indium) does not use flux for soldering, and the vibration energy allows the solder to penetrate very small gaps without generating tiny bubbles inside the solder (indium), thus achieving perfect soldering (sealing).
• Helpless soldering flux welding will not cause defects in the welded joint due to strong corrosion of the flux.
• By using ultrasonic vibration to allow solder to penetrate into small gaps, the welded joint is firm and reliable.

3. Save production costs and improve production efficiency

• Using aluminum wire instead of expensive copper wire can greatly save costs (saving 80%).
• Due to the absence of soldering flux, there is no need for pre-treatment or flux related processes, which can save equipment and production costs, simplify soldering processes, and improve production efficiency.

4. Support the development of new materials and products

• Successfully welding materials such as glass, ceramics, aluminum, and non-metallic materials that are difficult to weld using traditional welding methods can contribute to the development of new materials.
• Suitable for solar cell glass, semiconductor, and ceramic heaters, easy to weld for dual materials (aluminum copper, copper glass, aluminum glass, aluminum ceramic), and helpful for the development of new products.

 

 

Attention: The surface cleanliness of welded parts has a significant impact on welding performance. It is recommended to clean the welding surface with acetone before welding to achieve better welding results.