Ultrasonic Solder Powder Production MPI Providing innovative - - PowerPoint PPT Presentation

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Ultrasonic Solder Powder Production MPI Providing innovative - - PowerPoint PPT Presentation

Mar 24, 2024 256 likes •607 views

MPI Providing innovative ultrasonic solutions Ultrasonic Solder Powder Production MPI Providing innovative ultrasonic solutions Ultrasonic Technology Principle of capillary-wave atomization: Vibration amplitude creates standing

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SLIDE 1

Ultrasonic Solder Powder Production

MPI

Providing innovative ultrasonic solutions

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SLIDE 2

Ultrasonic Technology

Principle of capillary-wave atomization:

Vibration amplitude creates standing capillary waves. On further increase of the amplitude, ligament

breakup of the liquid follows and droplets are hurled from the crests of the capillary waves.

Drop size is correlated to sonotrode frequency,

amplitude, liquid physical properties, and liquid-film thickness.

MPI

Providing innovative ultrasonic solutions

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SLIDE 3

Ultrasonic Metal Atomization Limitations:

  • High Temperatures limit material selection &

dimensions for acoustical elements.

  • Material inefficiencies require the sonotrode to be as

close to the transducer as possible.

  • Such a configuration is problematic for ultrasonic

transducers that are inherently heat sensitive.

  • High temperatures combined with high amplitude

standing waves, ultrasonic cavitation, and chemical activity between liquid metal and the sonotrode are known to quickly degrade and severely limit the life of atomizing sonotrodes used in conventional ultrasonic metal atomization.

MPI

Providing innovative ultrasonic solutions

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SLIDE 4

Solder Powder Technology Development

Off-shoot of ongoing

ultrasonic atomizing development

Metal Powder Study

University Pilot Plant Study Metal Powder

Production

Based on MMM ultrasonic

technology

MPI

Providing innovative ultrasonic solutions

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SLIDE 5

Solder Powder Technology Development

2 year Development Effort Initial Work Based on MMM

University Project – Metal Atomizing General Atomizing Technology

New Enabling Ideas:

Improved Sonotrode Design Improved Transducer Placement Improved Alloy Feed & Flow Control Improved Chamber & Gas Control

MPI

Providing innovative ultrasonic solutions

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SLIDE 6

Additional Technology Development Results:

  • New Sonotrode Material
  • Improved Sonotrode Life
  • New Sonotrode Auto-Conditioning to

remove solder build-up.

  • New Sonotrode Induction Heating:

Simplified Placement Non-Contact Automatic Temperature

Control.

  • New Ultrasonic Cooling System
  • Higher Temperature Processing – Alloys

with melt point to 500° C

  • Hermetically tight atomizing chamber to

improve environmental security

MPI

Providing innovative ultrasonic solutions

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SLIDE 7

Additional Technology Development Results:

High Yield Type 3 (25 to 45 µm) powder

Distribution projection:

5 to 15 µm, : 5 % 15 to 25 µm, class 4: 5 % 25 to 45 µm, class 3: 65 to 70% 45 to 75 µm, class 2: 15 % 75 to 200 µm, : 5 %

System adaptable to next phase

ultrasonic equipment required for Type 4 powder.

Production Volume:

80 to 100 kg/hour for type 3 powder. Future development should push flow rate

150 to 200 kg/hour for type 3 powder.

MPI

Providing innovative ultrasonic solutions

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SLIDE 8

Production Projections:

  • 1 System Annual Production Type 3 powder @

90 kg/hr x 240 days:

  • 5 to 15 µm : 13 tons

15 to 25 µm, class 4 : 13 tons 25 to 45 µm, class 3 : 182 tons 45 to 75 µm, class 2 : 39 tons 75 to 200 µm

: 13 tons

  • 1 System Annual Production Type 3 powder @

180 kg/hr x 240 days:

  • 5 to 15 µm : 26 tons

15 to 25 µm, class 4 : 26 tons 25 to 45 µm, class 3 : 364 tons 45 to 75 µm, class 2 : 78 tons 75 to 200 µm

: 26 tons

MPI

Providing innovative ultrasonic solutions

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SLIDE 9

Project Status

Ultrasonics System

Sonotrode Design for type/class 3

powder (25 to 45 µm): Complete

Design for type/class 4 powder

  • interchangeable. Design work to be

complete in parallel with 1st system.

Rotational System Complete Generator, Converter, Booster

System Complete

MPI

Providing innovative ultrasonic solutions

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SLIDE 10

Project Status

Alloy Melt & Feed System:

Design Complete

Atomizing Chamber:

Design Complete

Gas Circulation & Control:

Design Complete

System Control:

Design Complete

MPI

Providing innovative ultrasonic solutions

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SLIDE 11

System Components - Plate Sonotrode

MPI

Providing innovative ultrasonic solutions

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SLIDE 12

System Components - Plate Sonotrode (video)

MPI

Providing innovative ultrasonic solutions

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SLIDE 13

System Components - Univ. Pilot Plant

MPI

Providing innovative ultrasonic solutions

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SLIDE 14

System Components Advanced FEA Modeling

MPI

Providing innovative ultrasonic solutions

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SLIDE 15

System Components Advanced Modeling Designs

MPI

Providing innovative ultrasonic solutions

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SLIDE 16

System Components Induction Melt Oven

MPI

Providing innovative ultrasonic solutions

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SLIDE 17

System Components Advanced Modeling Designs

MPI

Providing innovative ultrasonic solutions

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System Components Ultrasonic Rotational System

MPI

Providing innovative ultrasonic solutions

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System Components Advanced Modeling Designs

MPI

Providing innovative ultrasonic solutions

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System Components Advanced Modeling Designs

MPI

Providing innovative ultrasonic solutions

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System Components Advanced Modeling Designs

MPI

Providing innovative ultrasonic solutions

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SLIDE 22

System Components Advanced Modeling Designs

MPI

Providing innovative ultrasonic solutions

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SLIDE 23

System Components Advanced Modeling Designs

MPI

Providing innovative ultrasonic solutions

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SLIDE 24

System Components Advanced Modeling Designs

MPI

Providing innovative ultrasonic solutions

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SLIDE 25

System Components Advanced Modeling Designs

MPI

Providing innovative ultrasonic solutions

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SLIDE 26

System Components Advanced Modeling Designs

MPI

Providing innovative ultrasonic solutions

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SLIDE 27

System Components New Atomizing Plate Design

MPI

Providing innovative ultrasonic solutions

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SLIDE 28

System Components New Atomizing Plate Design

MPI

Providing innovative ultrasonic solutions

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New Atomizing Options MMM Pipe-Clamp Technology

MPI

Providing innovative ultrasonic solutions High Volume Powder

Production

Non-Specific Size Low Cost Sonotrode

(2 inch Pipe Shown)

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New Atomizing Options MMM Pipe-Clamp Technology

MPI

Providing innovative ultrasonic solutions

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New Atomizing Options

MMM Pipe-Clamp Technology

MPI

Providing innovative ultrasonic solutions High Temperature

Ceramic Alloy

Material Rated up

to 1200° C

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SLIDE 32

New Atomizing Options

High Temperature Sonotrode

MPI

Providing innovative ultrasonic solutions High Temperature

Alloy

Material Rated up

to 1200° C

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New Atomizing Options MMM Pipe-Clamp Technology

  • High Volume Solder Powder

Production

  • Non-Specific Size
  • Low Cost Sonotrode

(2 inch Pipe Shown)

MPI

Providing innovative ultrasonic solutions