Forum for Science, Industry and Business

Sponsored by:     3M 
Search our Site:

 

Industry and research join forces to improve bonding processes in the automotive industry

09.12.2013
In power electronics systems bonded connections create the central electrical connections between adjoining surfaces.

The quality of these bonded connections is one of the main factors that determines the reliability and availability of drive systems in electric vehicles, and hence constitutes a major design challenge for German auto manufacturers aiming to electrify their vehicles.


Laser-guided bonding head
Source: Fraunhofer ILT, Aachen, Germany


Laser-welded copper ribbon bond.
Source: Fraunhofer ILT, Aachen, Germany

Now the partners participating in the RoBE (Robust Bonds in Electric Vehicles) collaborative research project have developed a reliable means of predicting the service life of these bonded connections, and also developed an alternative bonding technique based on laser micro welding that is ready for industrial implementation.

The new technique opens up a wider range of options for the use of wire bonding, especially in applications requiring the joining of copper. Here, modern laser sources with a very high beam quality ensure precise, reproducible weld joints in copper and aluminum. Through the additional use of oscillation welding in combination with adapted design of the wire and ribbon joining zones, the strength of the joint can be improved still further. By comparison with conventional wire bonding, this process offers a higher surface quality and requires less cleaning. Moreover, the process is less dependent on the nature of the underlying surface or the vibration characteristics of the workpiece.

A standard bonding machine was adapted to allow the laser bonding process to be combined with traditional bonding technologies. The new machine now allows the use of a laser in the bonding process. The main applications of this system include ribbon bonding on DCB substrates and copper terminals in the packaging of power electronics assemblies.

Advances in the field of wire bonding technologies that extend the range of design opportunities while at the same time reducing costs are a vital factor in Germany’s future as a leading provider of electromobility solutions. For this reason, since August 1, 2011 the German Federal Ministry of Education and Research (BMBF) has set aside €4.96 million in funding to support this collaborative project as part of its ICT 2020 initiative in the category “Key technologies for electromobility” (STROM).

Contacts

Dr. Alexander Olowinsky
Head of the Micro Joining Group
Phone +49 241 8906-491
alexander.olowinsky@ilt.fraunhofer.de
Dipl.-Ing. Benjamin Mehlmann
Micro Joining Group
Phone +49 241 8906-613
benjamin.mehlmann@ilt.fraunhofer.de
Fraunhofer Institute for Laser Technology ILT
Steinbachstraße 15
52074 Aachen, Germany

Petra Nolis | Fraunhofer-Institut
Further information:
http://www.ilt.fraunhofer.de

More articles from Automotive Engineering:

nachricht Improvement of the operating range and increasing of the reliability of integrated circuits
09.11.2016 | Technologie Lizenz-Büro (TLB) der Baden-Württembergischen Hochschulen GmbH

nachricht New algorithm for optimized stability of planar-rod objects
11.08.2016 | Institute of Science and Technology Austria

All articles from Automotive Engineering >>>

The most recent press releases about innovation >>>

Die letzten 5 Focus-News des innovations-reports im Überblick:

Im Focus: Novel silicon etching technique crafts 3-D gradient refractive index micro-optics

A multi-institutional research collaboration has created a novel approach for fabricating three-dimensional micro-optics through the shape-defined formation of porous silicon (PSi), with broad impacts in integrated optoelectronics, imaging, and photovoltaics.

Working with colleagues at Stanford and The Dow Chemical Company, researchers at the University of Illinois at Urbana-Champaign fabricated 3-D birefringent...

Im Focus: Quantum Particles Form Droplets

In experiments with magnetic atoms conducted at extremely low temperatures, scientists have demonstrated a unique phase of matter: The atoms form a new type of quantum liquid or quantum droplet state. These so called quantum droplets may preserve their form in absence of external confinement because of quantum effects. The joint team of experimental physicists from Innsbruck and theoretical physicists from Hannover report on their findings in the journal Physical Review X.

“Our Quantum droplets are in the gas phase but they still drop like a rock,” explains experimental physicist Francesca Ferlaino when talking about the...

Im Focus: MADMAX: Max Planck Institute for Physics takes up axion research

The Max Planck Institute for Physics (MPP) is opening up a new research field. A workshop from November 21 - 22, 2016 will mark the start of activities for an innovative axion experiment. Axions are still only purely hypothetical particles. Their detection could solve two fundamental problems in particle physics: What dark matter consists of and why it has not yet been possible to directly observe a CP violation for the strong interaction.

The “MADMAX” project is the MPP’s commitment to axion research. Axions are so far only a theoretical prediction and are difficult to detect: on the one hand,...

Im Focus: Molecules change shape when wet

Broadband rotational spectroscopy unravels structural reshaping of isolated molecules in the gas phase to accommodate water

In two recent publications in the Journal of Chemical Physics and in the Journal of Physical Chemistry Letters, researchers around Melanie Schnell from the Max...

Im Focus: Fraunhofer ISE Develops Highly Compact, High Frequency DC/DC Converter for Aviation

The efficiency of power electronic systems is not solely dependent on electrical efficiency but also on weight, for example, in mobile systems. When the weight of relevant components and devices in airplanes, for instance, is reduced, fuel savings can be achieved and correspondingly greenhouse gas emissions decreased. New materials and components based on gallium nitride (GaN) can help to reduce weight and increase the efficiency. With these new materials, power electronic switches can be operated at higher switching frequency, resulting in higher power density and lower material costs.

Researchers at the Fraunhofer Institute for Solar Energy Systems ISE together with partners have investigated how these materials can be used to make power...

All Focus news of the innovation-report >>>

Anzeige

Anzeige

Event News

ICTM Conference 2017: Production technology for turbomachine manufacturing of the future

16.11.2016 | Event News

Innovation Day Laser Technology – Laser Additive Manufacturing

01.11.2016 | Event News

#IC2S2: When Social Science meets Computer Science - GESIS will host the IC2S2 conference 2017

14.10.2016 | Event News

 
Latest News

UTSA study describes new minimally invasive device to treat cancer and other illnesses

02.12.2016 | Medical Engineering

Plasma-zapping process could yield trans fat-free soybean oil product

02.12.2016 | Agricultural and Forestry Science

What do Netflix, Google and planetary systems have in common?

02.12.2016 | Physics and Astronomy

VideoLinks
B2B-VideoLinks
More VideoLinks >>>