Process Welding Configuration

Automated welding is a staple of the modern production environment. Yet different processes – i.e., implementations – demand vastly different tools. Automobile manufacturers, for instance, often employ laser or plasma welders attached to robotic arms – file footage many of us are familiar with from recent economic news. Other applications require greater sophistication so that the weld itself does not interfere with the functionality of the finished product.

For many of these applications, manufacturers’ materials and products require that welds not only be very precise or very small; many the weld itself – essentially a bond of melted material – must be free of contaminants or warping so that the finished good can function as intended. In the semiconductor manufacturing environment especially, the welding environment must be purged with inert gas to “shield” the arc from atmospheric gases that can make their way into the arc itself or contaminate the weld itself.

Executing this weld requires special weld heads that are capable of fitting tightly to the material to be welded – e.g., a tube, component, or substrate – to create a seal. The space around the weld is then purged with an inert gas or gas mixture. Gas argon is most commonly employed. The weld head produces a small channel of conductive gas inside the “shield gas” through which electric current is conveyed by a tungsten electrode, thereby creating an arc of consistent size and temperature. The channel of conductive gas and the tungsten electrode can be programmed to move according to precise instructions to execute a weld that is free contaminants and is consistent in quality – both properties being essential to the proper functioning of semiconductor components.

Yet weld heads are not only available for GTAW or TIG welding. As mentioned, there is a design suited to nearly any process (or otherwise the potential for an inventor to become very rich filling the gap), and energy for a weld can be conveyed through laser, plasma, etc.

When purchasing a weld head for a process, buyers who only consult with an OEM do themselves a disservice. Vendors of equipment from multiple OEMs have the expertise to choose the right tool for the process, and those who also have experience in repair and re-manufacturing may be able to offer a remanufactured weld head at a fraction of the price of a new one purchased from an OEM, without any sacrifice in quality.