In the field of precision manufacturing, the reliable connection of micro-sized metal wires is a key link for the normal operation of many high-end devices. Among them, the connection requirements for platinum-tungsten coils containing 92% platinum and 8% tungsten , and silver alloy wires containing 99% silver and 1% magnesium , due to the differences in material properties and the miniaturization of wire sizes, pose extremely high demands on the connection process. The ultrasonic brazing system, with its unique technical advantages, has become an ideal solution for the connection of such dissimilar metal wires, providing efficient and reliable process support for the precision manufacturing industry.
As a high-performance precious metal alloy, platinum-tungsten alloy combines the excellent electrical conductivity and chemical stability of platinum with the high strength and high-temperature resistance of tungsten. Its ultra-fine coil diameter of 0.02mm makes it play an irreplaceable role in fields such as micro-sensors and precision electronic components. The silver alloy wire containing 1% magnesium retains the excellent electrical conductivity of silver while the addition of magnesium further enhances the mechanical strength and corrosion resistance of the alloy. Combined with a wire diameter of 0.06mm and an ETFE coating design, it not only meets the requirements of electrical transmission but also has good environmental adaptability, and is widely used in signal transmission lines of high-end electronic equipment. However, the composition differences and ultra-fine size characteristics of the two materials pose many challenges to the traditional joining process.
The traditional brazing process is prone to problems such as high-temperature oxidation and grain growth. For platinum-tungsten alloys, which have excellent heat resistance but are prone to brittleness at high temperatures, excessively high welding temperatures will seriously affect their mechanical properties and electrical conductivity stability. The magnesium element in silver alloy wires is volatile at high temperatures, causing the joint composition to deviate from the design requirements and reducing the connection reliability. In addition, the diameter difference between the 0.02mm platinum-tungsten coil and the 0.06mm silver alloy wire is relatively small, and both belong to ultra-fine specifications. The traditional mechanical connection method is prone to cause deformation and breakage of the wire, and cannot ensure the consistency and stability of the connection.
The core advantage of the ultrasonic brazing system lies in its ability to connect dissimilar metals by utilizing the mechanical vibration energy of high-frequency ultrasonic waves, without relying on high-temperature heat sources, effectively avoiding the drawbacks of traditional processes. During the connection process, ultrasonic waves are converted into high-frequency mechanical vibrations through the transducer and act on the contact interface between the platinum-tungsten coil and the silver alloy wire, breaking the oxide film at the interface and promoting the diffusion and bonding between metal atoms, thus forming a firm metallurgical bonding joint. During this process, the temperature in the joint area is relatively low, which not only avoids the embrittlement of the platinum-tungsten alloy and the volatilization of magnesium in the silver alloy, but also retains the original properties of the two materials to the greatest extent.
For the connection of 0.02mm platinum-tungsten coils and 0.06mm silver alloy wires with ETFE coating, the ultrasonic brazing system can achieve effective interface combination by precisely regulating parameters such as vibration frequency, amplitude and pressure. The ETFE coating can be rapidly peeled off under the local frictional heat generated by ultrasonic vibration without affecting the contact and bonding at the metal interface. Meanwhile, reasonable setting of process parameters can prevent the ultra-fine wire from deforming or breaking during the connection process, ensuring the dimensional accuracy and connection strength of the joint. After practical application verification, the platinum-tungsten coil and silver alloy wire joint connected by ultrasonic brazing technology has excellent electrical conductivity, mechanical properties and corrosion resistance. The joint strength can reach more than 85% of the base material strength, fully meeting the usage requirements of precision electronic equipment.
In high-end manufacturing fields such as aerospace, medical equipment, and precision instruments, the demand for the connection of ultra-fine specification dissimilar metal wires is increasing day by day. The successful application of ultrasonic brazing systems in the connection of platinum-tungsten coils and silver alloy wires not only provides a reliable process solution for this specific material combination but also offers an important reference for the connection of other ultrafine dissimilar metal wires. With the continuous development of precision manufacturing technology, ultrasonic brazing systems will further expand their application scope through process optimization and equipment upgrading, providing strong support for the high-quality development of high-end manufacturin
