Ultrasonic Soldering for Joining Dissimilar Materials September 14

Ultrasonic Soldering for Joining Dissimilar Materials September 14, 2011 Kirk Cooper Senior Engineer, Materials Email: kcooper@ewi. org Phone: 614. 688. 5069

What’s so exciting about soldering?

This is!

Outline ― What is ultrasonic soldering and how does it work? ― What’s the advantage of using ultrasonic soldering? ― What is EWI Sonic. Solder™? ― What can I join using ultrasonic soldering? ― What are some examples of ultrasonic soldering between dissimilar materials?

Ultrasonic Soldering ― Ultrasound energy (20 k. Hz and up typical) generates cavitation ― Cavitation erodes surface oxide, lowering surface energy thereby enabling wetting by the molten solder ― Bonding occurs by: u u ― Van der Waal’s forces: electrostatic attraction Metallic bond: electron sharing Filler metal melts below 450°C

Ultrasonic Solder Pots u Transducers are attached to heated pot or immersed at the surface u Parts are pretinned by dipping Two different pot designs

Ultrasonic Soldering Irons Misonix ― Much like a conventional iron except the tip can be ultrasonically energized 30 -k. Hz soldering iron Bellex Int. ― Operating frequency 60 k. Hz ― Typical power levels <30 W 20 - 60 -k. Hz soldering iron

Custom Soldering Iron EWI-designed large-scale ultrasonic soldering iron with 1 -in. -wide horn Power levels up to 300 W

EWI Expertise…. Scale-Up u u EWI has developed larger tools to increase process speed Larger sonotrode designs require more ultrasonic power, but are required to increase pass width Sonotrode Scale-Up: 1 - to 4 -in. wide, 1200 -W ultrasonic power

Process Basics u ─ u u Electrically heated iron tip Part and soldering iron tip must be heated Typically 20 -30°C above solder liquidus Soldering iron tip must be wet with solder alloy Soldering iron must be ultrasonically activated while in contact with the work piece Both pieces are wetted with solder Join while solder remains liquid or solidify and reflow Hot Plate Ultrasonic pretinning oxidized Ti-6 -4

Advantages of Ultrasonic Soldering ― Fluxless u u u ― Ability to join “unsolderable” materials u u u ― ― ― No pre-fluxing No post-cleaning No corrosive flux residue Ferrous metals Non-ferrous metals Glasses Ceramics Graphite Composites No metalizing or plating required Typically no controlled atmosphere required Ability to join dissimilar materials

Key Advantages…. Capable of Joining Dissimilar Materials u EWI patented Sn-based soldering alloy for difficult-to-wet material ─ ─ Heavily Oxidized Metals Ti, Ni, Au, Ag, Pt, Al, Cu, SS, Fe, etc. Al 2 O 3, Si. C, WC, BC, nitrides, etc. Heavily oxidized or anodized metals Glass, carbon foams, exotic materials Glass-to-Metal Joint Ti-Al structural joint Ti 6 -4 Al 2219 25 -mm Si. C to Ti-6 -4 Glass-to-Ceramic Seal

Key Advantages…. Selectively Solders Complex Shapes, Sizes u Various shapes and sizes can be easily pretinned with Sonic. Solder™ and the ultrasonic soldering process 16 - × 16 -in. Ti-to-Ceramic Ballistic Panel Al to Cu Al Tube to Anodized Fitting

EWI Expertise…. FEA-Aided Sonotrode Design u FEA analysis allows development of new sonotrodes tailored to specific applications Sample FEA Designs u In-house CAD design and machining expedites the developmental process CAD Drawings Prototype Sonotrodes

EWI Sonic. Solder™ ― EWI developed a Sn-based soldering alloy for use on difficult to wet materials: u u u u EWI-patented, high Sn solder alloy Active metal addition enables wetting on Ti alloys, Al alloys, glass, and ceramics Pb-free All constituents are low-cost metals Alloy is produced with conventional melting practices Melting temperature ~230°C Shear strengths up to 6 ksi Higher strength modifications are possible

Case Study: Aluminum to Steel ― ― Background: Lightweighting for automotive applications calls for joints between aluminum and steel sheet for deck lids and roof/pillar junctions Problem: Aluminum and steel form brittle intermetallics when fusionwelded Solution: Ultrasonically coat aluminum with Zn-Al alloy; spotweld to galvanized steel Result: Minimal intermetallic layer; shear strength up to 25 ksi

Case Study: Steel to Ceramic ― Background: Demanding application requires wear-resistant Si. Cdiamond (SCD) ceramic bonded to steel ― Problem: Joint geometry and CTE mismatch require low -temperature, highstrength bond ― Solution: Use Zn-5 Al steel SCD Microstructure of Si. Cdiamond ceramic (courtesy of Element Six) C-scan image shows a sound joint

Case Study: ZAO to Stainless Steel ― Background: Solar industry bonds zinc aluminum oxide (for thin-film PV) to stainless steel supports using indium + flux ― Problem: Indium is expensive (~$20/oz) vs tin (~$0. 60/oz) ― Solution: Ultrasonically solder

Case Study: Titanium to Carbon Fibers ― ― Background: Advanced aircraft incorporate titanium and carbon fiber composites for light, stiff structures Problem: Conventional approaches such as adhesive bonding do not exhibit sufficient strength over the full operating temperature range Solution: Ultrasonically solder CP Ti to graphite fiber tow using EWI Sonic. Solder™ Result: Joints submitted to client for testing

Summary ― Ultrasonic soldering is a fluxless process which works with any solid material ― EWI Sonic. Solder™ has enabled joining of unique dissimilar material combinations ― Higher-temperature solders have also been successfully used in ultrasonic joining ― Extension into ultrasonic brazing (T > 450°C) has also been demonstrated (e. g.

Questions? Kirk Cooper Senior Engineer, Materials Email: kcooper@ewi. org Phone: 614. 688. 5069