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 3D scans for the automotive industry
16.01.2017 | Julius-Maximilians-Universität Würzburg

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

All articles from Automotive Engineering >>>

The most recent press releases about innovation >>>

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

Im Focus: Quantum optical sensor for the first time tested in space – with a laser system from Berlin

For the first time ever, a cloud of ultra-cold atoms has been successfully created in space on board of a sounding rocket. The MAIUS mission demonstrates that quantum optical sensors can be operated even in harsh environments like space – a prerequi-site for finding answers to the most challenging questions of fundamental physics and an important innovation driver for everyday applications.

According to Albert Einstein's Equivalence Principle, all bodies are accelerated at the same rate by the Earth's gravity, regardless of their properties. This...

Im Focus: Traffic jam in empty space

New success for Konstanz physicists in studying the quantum vacuum

An important step towards a completely new experimental access to quantum physics has been made at University of Konstanz. The team of scientists headed by...

Im Focus: How gut bacteria can make us ill

HZI researchers decipher infection mechanisms of Yersinia and immune responses of the host

Yersiniae cause severe intestinal infections. Studies using Yersinia pseudotuberculosis as a model organism aim to elucidate the infection mechanisms of these...

Im Focus: Interfacial Superconductivity: Magnetic and superconducting order revealed simultaneously

Researchers from the University of Hamburg in Germany, in collaboration with colleagues from the University of Aarhus in Denmark, have synthesized a new superconducting material by growing a few layers of an antiferromagnetic transition-metal chalcogenide on a bismuth-based topological insulator, both being non-superconducting materials.

While superconductivity and magnetism are generally believed to be mutually exclusive, surprisingly, in this new material, superconducting correlations...

Im Focus: Studying fundamental particles in materials

Laser-driving of semimetals allows creating novel quasiparticle states within condensed matter systems and switching between different states on ultrafast time scales

Studying properties of fundamental particles in condensed matter systems is a promising approach to quantum field theory. Quasiparticles offer the opportunity...

All Focus news of the innovation-report >>>

Anzeige

Anzeige

Event News

Sustainable Water use in Agriculture in Eastern Europe and Central Asia

19.01.2017 | Event News

12V, 48V, high-voltage – trends in E/E automotive architecture

10.01.2017 | Event News

2nd Conference on Non-Textual Information on 10 and 11 May 2017 in Hannover

09.01.2017 | Event News

 
Latest News

Tracking movement of immune cells identifies key first steps in inflammatory arthritis

23.01.2017 | Health and Medicine

Electrocatalysis can advance green transition

23.01.2017 | Physics and Astronomy

New technology for mass-production of complex molded composite components

23.01.2017 | Process Engineering

VideoLinks
B2B-VideoLinks
More VideoLinks >>>