Electronics - Sensor Welding
Sensor assembly requires some very high technology in both sensing technology and packaging to create a robust, small, and accurate system that can survive in a hostile environment. In the past these sensors could be larger and employ gaskets or other mechanical seals. Today with the need for sensors to optimize operation and safety in everything from spacecraft to consumer goods, the requirement for a low cost, low heat input joining method is critical.
These sensors can involve very sensitive electrical and mechanical transducers along with temperature sensitive parts and seals so sealing them against the elements must be done with a reliable, low heat-input, system; all at low cost.
Laser welding meets these requirements. A laser weld of quality components is a hermetic seal so that no contaminants can reach the sensors or pressure transducers and the proper reference pressure will always be preserved. Laser welding has very low heat input and can be placed very close to polymer seals, glass-to-metal seals, soldered components, and electronic circuits. Integration of a laser system into a sensor welding line is simple with minimal control requirements, non-contact, with very a robust process window and almost no consumables or adjustments when compared to micro-tig, resistance welding, or brazing. Many different materials can be laser welded. Most often stainless steels, mild steels, kovar, titanium, and super alloys are employed.
Time-Share Multiplexing to send the output from one laser to multiple workstations down different fibers can be used to best make use of the laser system. The welding parameters can be changed faster than the 50msec switching time between fibers. CCTV through the lens viewing can be used to align and monitor the targeting of the laser beam.
Both Super Modulated CW YAG lasers and pulsed YAG lasers can be used for sensor welding. Most applications can employ either system but for very high throughput the CW and Super Modulated CW lasers will produce the highest welding rates at the lowest cost with low heat input. For very small devices where heat input is critical or where the alloys are more reflective like aluminium or gold plated parts a pulsed YAG is often the best choice. It has the peak power to weld these reflective materials and can weld to deep penetrations at low average power.
Typical lasers that have been used for this application
JK125P, JK300P & JK300HP
For Fiber-Delivered Cutting, Welding, Heat Treating
JK2003SM
Lamp-Pumped Nd:YAG, 2000W, 4000W with SuperModulation
JK401SM & JK501SM
Lamp-Pumped Nd:YAG, 400 & 500W, 800 & 1000 with SuperModulation
JK450HP & JK600HP
Lamp-Pumped Nd:YAG, 450 & 600W
JK802 & JK1002
Lamp-Pumped Nd:YAG, 800 & 1000W, 1600 & 2000 with SuperModulation
Please call us to discuss lasers for your specific application
Click here for expert advice on Electronics applications.