2. "Droplet Weld" an environmentally friendly, lead - free joining technology using metal droplets
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Abstract: Main results of the Droplet Weld project can be summarised as follows:
-An arc droplet welding touch & retract laboratory prototype has been developed.
This device is able to form molten droplets, of diameters>1mm, out of standard wire and place the molten metal droplets accurately onto a substrate in order to produce a weld.
-A laser droplet welding laboratory prototype has been developed.
This device is able to form molten droplets, of diameters<1mm, out of standard wire and place the molten metal droplets onto a substrate in order to produce a weld.
Targeted use is an industrial production setting in which accurate and reproducible joints have to be made quickly. Benefit is that cost of the system is low.
Subject Descriptors: Microelectronics; Microcomputers; Microprocessors; Laser technology; Metals, alloys; Civil engineering; Process engineering; Chemical engineering
Subject Index Codes: Industrial Manufacture; Construction Technology; Materials Technology; Information Processing, Information Systems; Other Technology; Electronics, Microelectronics
Market Applications: Metal products (ferrous, nonferrous)
Stage of Development: Experimental development stage (laboratory prototype)
Collaboration Sought: Further research or development support
Collaboration Detail: Interested industrial end-users sought, for which Philips CFT can do the final equipment/process development. Development effort is estimated several man months of work. Equipment cost per unit is low.
The Arc Droplet Welding can be used in fabrication for different joining applications. The benefit is that a lead free joint is produced.
The parts to be welded should be thermoshock resistant to a certain extent. For a successful weld, size of the droplet should match with the thermal dissipation behaviour of the weld. This requires application development.
In case of collaboration, Philips CFT can play the role of system integrator and process/application developer. The Laser Droplet Welding can be used in fabrication for different joining applications. A substantial advantage is the possibility to bridge gaps between the joining partners with the help of the droplet material, which makes the complex realization of a technical zero-gap unnecessary. Further advantages are the possibility to work with high reflective materials, the production of high temperature joints, the use of lead free materials and the possibility to join different materials. The process is particularly interesting for sensitive joining applications e.g. thin foils. By further development of this technology new joining applications will become realisable. The only limitation is the geometry and the mass of the joining partners: if the heat dissipation is too high the energy of the droplet is not sufficient to melt and join the partners.