Ultrasonic welding of electronic parts and devices using a long and thin complex vibration welding tip

Ultrasonic complex vibration welding was applied for deep and narrow area of electronic parts positioned at long distance from the vibration system. Usually, electric resistance welding was used to weld such part, but there are possible defect caused by sparked metal particles radiated from welding position. To overcome the defect and make possible to join such deep area, 20 kHz and 27 kHz ultrasonic complex vibration systems using 2.0- and 3.0-mm-diameter, 70- to 100-mm-long hard metal and tungsten welding tips were developed. Using the ultrasonic complex vibration systems, various metal specimens including copper, nickel clad copper terminal and steel or nickel coated steel cases were successfully welded with weld strength almost equal to these material strength.