NPTEL Online Certification Course

Advances in welding and joining technologies

Assignment Number 05: Detailed Solution
Indian Institute of Technology Guwahati

1) Classification of microjoining process

Category
Solid-state bonding
Soldering or brazing
Fusion welding
Adhesive bonding
Microjoining process
Ultrasonic wire bonding, Diffusion bonding
Eutectic soldering, Fluxless soldering, Laser reflow
Electron and laser beam, Plasma, Glass sealing
Adhesive flip chip, Adhesive die attachment

2) Fusion micro-welding basically classified into two categories:

• Arc welding
➢ Regulated and controllable outputs of less than 1 amp.
➢ Mainly consists of gas tungsten and plasma arc welding
➢ Peak pulse controls the penetration
➢ Background pulse allows solidification without extinguishing the arc
• Power beam welding
➢ Very fine control over power and positioning
➢ Focus a high energy beam onto a very small spot size
➢ Deep penetration with little distortion
➢ Mainly consists of laser beam welding (performs under inert gas atmosphere)
and electron beam welding (performs under vacuum)
3) Laser beam welding is a non-contact type joining process with very little distortion, and
narrow heat affected zone. This occurs due to precise controls of laser heat source that rapidly
heats the material having typically evaluated in milli seconds.
4) Basically, there are three modes of plasma arc welding (PAW) classified on the basis of
current during fabrication:
• Micro-plasma (less than 15 Amperes)
• Melt-in mode (15-400 Amperes)
• Keyhole mode (greater than 100 Amperes)
5) In ultrasonic bonding process, normally high frequency vibration with a low pressure to cause
plastic flow. Interfacial oxides and contaminants are displaced, and by applying pressure
bonding formation takes place between two materials.
Following are the application of ultrasonic bonding process:
• Commonly used for plastics, and especially for joining dissimilar materials.
• It is more useful for joining when materials are susceptible to deformation or
cracking.
6) Based on the shear strength (Tresca yield criterion) of the joints, bonding strength of the
material is given by:
𝐴𝑔 > 𝐶𝑢 > 𝑁𝑖 > 𝑇𝑖 > 𝐴𝑙
7) Utilization of rectangular pulse in ultra-short pulse laser welding facilitates the uniform
distribution of accumulated heat that leads to the reduction in concentrated tensile residual
stress in narrower region as it occurs in case of triangular pulse.
8) By modulating the frequency of pulse, maximum power can be controlled in case of pulsed
current plasma arc welding.
9) Materials and its corresponding joining methods:
Materials Joining methods
Tantalum Laser welding
Kovar alloy Resistance welding
Silicone Adhesive bonding
Lead free solders Brazing

10) Following are the different phases of laser micro-welding process:

• Droplet creation
• Droplet detachment
• Droplet flight
• Droplet landing
• Droplet solidification