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At present, in the fields of electronic manufacturing, new energy and high-end equipment, the tinning process for metal wire harness heads and lug ends will be adopted during the product production process. This technology determines the mechanical strength of the welding point and affects the reliability and market competitiveness of the overall product. The traditional tinning process relies on manual operation (electric heating gun) and chemical flux (rosin), and has problems such as low efficiency, strong odor, manual control of temperature/dosage, different characteristics of suitable welding materials, and the need for pretreatment of welding material surfaces. The emergence of a new generation of ultrasonic tinning machines is leading a subversive process revolution with its characteristics of no chemical pollution, uniform tinning, and a wide range of suitable welding materials.

1. Technical principle:synergistic breakthrough of ultrasonic vibration and cavitation effect

The core of ultrasonic tinning machine is to use the high-frequency vibration (usually 20-30kHz) and cavitation effect generated by ultrasonic waves to act on the tin liquid to achieve the cleaning and welding of the metal welded parts surface. Its principle can be decomposed into two steps:

Oxide layer stripping:

Ultrasonic vibration causes tiny bubbles to be generated in the molten tin liquid. The shock wave (cavitation effect) released when the bubble bursts can strip the oxide layer on the metal surface, exposing the clean substrate without chemical flux or pretreatment, and achieving the requirements of dense tinning.

Tin liquid penetration:

Vibration energy pushes liquid tin into the metal micropores and gaps, eliminating welding bubbles. After the weldment is dipped for 3 to 10 seconds and then lifted and cooled, a dense and gapless coating is formed, which significantly improves the adhesion and sealing between welded parts or between tin and welded parts.

2. Core advantages:full-dimensional innovation from environmental protection to cost

a. Green environmental protection

Zero chemical pollution:

abandon traditional flux, avoid the emission of harmful substances such as phenol and hexavalent chromium, and reduce the pressure of cleaning wastewater treatment and exhaust gas emission.

Energy saving and consumption reduction:

Some equipment can reduce tin consumption by more than 30% (such as Sanfu Xinke tinning technology), while reducing auxiliary energy consumption (such as steam drying).

b. High efficiency and low cost

Material substitution:

replace copper wire with aluminum wire, saving 80% of wire cost, and supporting welding of heterogeneous materials such as aluminum-glass and aluminum-ceramic, promoting breakthroughs in application fields and development of new products.

Process simplification:

no pretreatment or flux cleaning process is required, the single tinning time is shortened to 2-3 seconds, the production efficiency is increased by more than 50%, and the technical requirements of traditional two-handed manual tinning are abandoned.

c. Wide applicability

Material compatibility:

It can weld materials that are difficult to handle with traditional processes such as glass, ceramics, and semiconductors, especially for high-end scenarios such as solar panels and new energy vehicle battery electrodes.

3. Industry application:comprehensive penetration from electronic manufacturing to new energy

Electronic components:

used for welding aluminum wires of motors and transformers, eliminating pin oxidation and tinning defects, and improving product yield.

Automotive electronics:

in the manufacture of sensors and controllers, ensure welding stability under high temperature and high pressure environments.

New energy field:

solve the problem of heterogeneous connection between photovoltaic glass and metal electrodes, and help produce efficient solar cells.

Aerospace:

through bubble-free welding process, meet the high sealing requirements of devices in extreme environments.

4. Conclusion

Ultrasonic tinning machine is not only a process revolution, but also a microcosm of the transformation of manufacturing industry to green and high-end. Through technological innovation and industrial collaboration, Chinese companies are turning from “following” to “leading”, injecting new momentum into global sustainable development. FUNSONIC provides free proofing activities to our customers and friends, from standard models to customized models, to the maximum extent possible from the customer’s perspective, to provide customer-satisfying services.

Media Contact
Company Name: Hangzhou FUNSONIC Ultrasonic Technology Co., Ltd.
Email: Send Email
Phone: 0086-18966176048
Address:No.16 Changtai Road, Changkou Town, Fuyang District
City: Hangzhou
State: Zhejiang
Country: China
Website: https://www.funsonic-tech.com/