What is wave welding? Wave soldering techniques in electronics manufacturing?
Wave soldering is an important and common process in electronics manufacturing, in order to connect electronic components to printed circuit boards efficiently. In this article, join RX Tradex to learn about what wave soldering concept and wave soldering techniques in electronics manufacturing today.
1. What is wave welding?
Wave soldering is an important method in electronics manufacturing, used to connect electronic components to printed circuit boards (PCBs) using high temperatures to melt solder and create conductive electrical connections. This process is carried out under the layer of molten solder, which creates a stream of welding waves.
Wave soldering is commonly used in connecting both through-hole components and surface-mounted components of printed circuit boards. In the case of piercing components, the components are placed in place on the printed circuit board and then the circuit board is passed through soldering waves to solder them to the circuit board.
2. Wave soldering techniques in electronics production today
2.1. Wave soldering with lead waves
Wave soldering with lead waves is considered one of the most traditional and popular soldering methods in electronics manufacturing, especially in connecting components with legs through printed circuit circuit holes. This soldering process is used to connect electronic components to PCB printed circuits.
The principle of wave soldering with lead waves is based on a layer of alloys containing lead and other metals that are melted to form a liquid flow, called a “lead wave”. The electronic components are placed on the surface of the PCB and passed through the hot lead wave. Due to the high temperature, lead waves melt and create strong conductive connections between components and printed circuits.
The lead wave soldering procedure is usually performed in a protective environment or under the flux layer (arc) to prevent oxidation and protect the surface of PCBs and components. After the wave soldering process is completed, the PCB printed circuit board is usually cooled and cleaned to remove lead and arc residues.
2.2. Wave welding with an arc
Arc wave soldering, also known as induction wave soldering. In contrast to lead wave soldering, this method does not use lead to make the connection, but instead, uses an arc (flux) and heat wave from an induced radiation to fuse the metal bonds.
This process uses an arc layer onto the surfaces that need to be soldered by PCBs and electronic components. When printed circuits and components are placed correctly, they are fed through a high-temperature region generated by an induced radiation, usually from an electromagnetic wave or made from fibre wires that trigger the arc, causing them to melt and create a liquid medium that helps the metal bonds melt and connect with each other.
One of the great advantages of arc wave welding is the ability to weld components of small size or complex structure without the use of lead, thereby minimizing or completely eliminating the risk of lead. In addition, the use of an arc eliminates environmental pollutants from lead and minimizes the consequences of harmful emissions to human health and the environment.
However, arc wave soldering also has some limitations, including inflexible temperature and contact time control capabilities like lead wave soldering, and may sometimes require more complex cooling and cleaning procedures after welding is completed.
2.3. Laser wave welding
Laser wave welding is a welding method performed by using a laser to create a high temperature at the welding point. This method is often used to weld components with small size and high precision, and provides high control over the depth and width of the weld point.
The laser wave welding process is performed using a laser generator to produce lasers that are highly focused and have enough energy to fuse metal bonds. When the laser is directed at the location to be welded, it creates a high temperature at the point of contact, causing the materials to melt and connect with each other.
Some of the advantages of laser wave welding include:
- High precision: The laser can be adjusted to produce weld points with precise dimensions and shapes, tailored to the specific requirements of each application.
- Ability to solder small components: Due to the high concentration of the laser, this method is suitable for soldering small-sized and high-precision components such as chips and integrated circuits.
- Temperature control: The laser can be precisely controlled to produce the temperature required for the welding process, which helps ensure the stability and evenness of the connection.
However, there are also some drawbacks to consider when using laser wave soldering, including high equipment costs, especially for mass production applications, as well as the potential effect of laser light on sensitive materials. For some materials, such as those that conduct electricity well, it may be necessary to use an adhesive or arc to minimize the impact of the laser on the surrounding environment.
2.4. Wave soldering with thermal sensors
Wave soldering with a thermal sensor is a method of using a thermal sensor to measure and control temperature during wave soldering. Thermal sensors strategically located on printed circuit board (PCB) surfaces or near necessary components measure the current temperature and adjust the parameters of the soldering process to ensure that the temperature reaches the level needed to solder circuits and components accurately and stably.
Using thermal sensors during wave soldering helps to adjust and control the temperature automatically and accurately, minimizing the risk of failure and ensuring the quality of the final product.
3. Why is wave soldering important in electronics manufacturing?
Wave welding is an important welding method in electronics manufacturing with many notable advantages such as providing high performance during the connection of electronic components, helping to enhance the reliability and performance of the product. Besides, this welding method also saves labor costs and production time, thereby improving productivity and reducing costs.
Wave soldering also ensures high reliability for electronic connections, helping the product operate stably and sustainably. The flexible processing capabilities of wave soldering allow the connection of electronic components of various sizes and shapes, from simple to complex. At the same time, the use of wave soldering also helps protect the working environment and people by not creating smoke, dust and toxic waste.
4. Conclusions
With the above article, RX Tradex has given an overview of what wave soldering is in and the popular wave soldering techniques today. In order not to miss out on leading manufacturing trends and knowledge in the industry, you can join NEPCON Vietnam to have the opportunity to discover the latest trends in the power generation industry, stay up to date with new industrial products and equipment and participate in technology seminars and industry demonstrations.
