Electronic manufacturing has always been a delicate task. There are many critical and small components to deal with in this process. As the industry and needs of the masses keep evolving, regular welding methods are deemed nearly useless here. However, laser welding electronic components can bring that accuracy and delicacy right into the table.
Laser welding has many uses, from joining microelectronics to working with unusual materials. In this article, we will look into how this welding method is proving to be the go-to option for welding electronic parts. We will also look at some key points and challenges that operators might need to deal with during the welding process.
Lasers for Welding in Electronics Manufacturing
Laser welding technology is developing and offering more benefits. Hence, its use is expanding annually. Let’s look at some excellent revolutions brought about by laser welding in electronics manufacturing:
Efficiency in Welding Microelectronics
The constant downsizing of electronic components necessitates ever-tinier solder joints. It also requires stronger welding and a smaller heat-affected zone surrounding the processing point. Unfortunately, traditional welding methods aren’t up to par to meet these standards. These methods have many downsides, such as
- Low welding efficiency
- Poor weld ring and welding site ring binding
Thankfully, the opposite is true with lasers. They can melt and mix the contact materials to create fusion. Lasers can be used to spot weld and seam weld small electrical parts precisely, which is used in the electronics industry. This technique allows for the joining of extremely small welding spots and fine welding seams.
Another method of joining electronic components and circuit boards is by using a laser soldering machine. This is essentially a laser welding process. Using a laser to melt tin creates a perfect solder joint in an instant.
Welding Exotic and Difficult to Weld Materials
Various materials, such as copper, gold, silver, nickel, Kovar, etc., can end up in an electronic package. It depends on the specifics of a requirement. Laser welding allows for the welding of a wide variety of materials. This includes materials that are difficult to work with or crack easily. This allows a wide range of material options for component packaging.
Minimizing Heat and Electrical Charge Damage
If you are making electronic parts, you no longer have to worry about heat stress or damage to difficult-to-work-with materials. That’s thanks to precision, automated, or manual laser welding. The electronic component parts are also guaranteed to last longer with laser welding. Pulse laser welders are the way to go for applications involving voltage sensitivity.
Durable Assemblies
It is critical to manufacture electronic assemblies for maximum durability. That’s because these assemblies encounter harsh environments. Depending on the use, some of these assemblies may be subjected to pressures exceeding 5,000 PSI. They may also be exposed to temperatures ranging from -400°F to +300°F. Laser welding can combat this environment brilliantly. Many unique applications utilize laser spot or seam welding in electronics manufacturing, such as-
- Pressure-sensitive hermetic laser seals
- High-precision industrial assemblies
- Complex electronic components
Moreover, the elimination of filler material during laser welding cuts costs. It also makes the process very amenable to automation. This allows for a more consistent and repeatable weld in electronic applications.
Key Points to Remember While Laser Welding Electronic Components
An important part of ensuring the quality of electronic products is laser welding parts together with an electric iron. However, when laser welding electronic products, there are some key points to remember.
- Prior to welding, the surface needs to be ground to a metallic finish using a knife. It also needs to be coated with a flux coating and, finally, a solder layer. Avoid acid flux at all costs. It will destroy the weld. Choose acid-free flux, rosin oil, or rosin as your preferred material.
- Make sure the electric iron gets hot enough to prevent long periods of inactivity and guarantee quality welding.
- Keep the soldering iron away from the joint for as little time as possible.
- You can not just move the welded parts around after the iron has withdrawn from the spot. Otherwise, the solder will be easy to remove.
- It is preferable to tie and tin the connected components first.
- Using nose pliers or tweezers to clip the transistor lead foot while welding is the best method for handling high-temperature devices like transistors. It is also important to master the art of keeping accurate time.
- Welding semiconductor components requires a short welding time and thin, low-temperature welding wire.
Welding Electronics Issues and Challenges
Getting equipped with the key points of welding isn’t enough. Even with the wonders of laser welding, certain issues keep on rising while welding electronics. These issues can single-handedly ruin the total welding process and outcome. Let’s look at them and their potential solutions:
Electrostatic Discharge (ESD)
Electrical devices are extremely vulnerable to damage from stray currents. Therefore, a clean room that is ESD-safe is required for any electronic welding. Also, operators need to keep learning how to safely and correctly handle electrical equipment and PCBs (printed circuit boards) according to industry standards.
Sensitivity to Oxygen and Moisture
Metals’ chemical and mechanical properties change as a result of oxidation. This results from an excess of oxygen and moisture. The internal components are vulnerable to short circuits and other problems caused by oxidation and corrosion. This can also severely compromise the electrical and mechanical integrity of the external packaging.
The use of a glovebox during welding operations, as well as vacuum baking assemblies before welding, can help avoid this. Compared to traditional sealing methods like solder, epoxy, and mechanical seals, vacuum baked assemblies excel in terms of performance. These assemblies come with oxygen and moisture levels below 1 ppm. The glovebox laser welding environment guarantees the complete absence of oxidizing contaminants in assemblies.
Conclusion
The use of laser welding has improved the speed and accuracy of making electronics. The process is now meeting the need for smaller, stronger solder joints. Traditional methods fall short due to low efficiency and poor results. In contrast, lasers are very good at melting materials to make strong fusions. This lets small electronic parts be welded precisely in spots and seams.
Besides, laser welding can be used on many types of materials, even ones that are hard to work with. In extreme temperatures, it reduces damage from heat and makes sure that the assemblies last. This is very important for electronics. However, there may be challenges. Take electrostatic discharge and sensitivity to oxygen and moisture as examples. These will require attention and mitigation strategies such as ESD-safe environments and vacuum baking assemblies.
But to get the most out of laser welds, the first thing to ensure is a top-quality laser welder. Fiber Laser Welder is pleased to offer welders like these. Our laser welders guarantee unmatched performance, efficiency, and accuracy. Contact us today to get your preferred machine.
