Analysis of Flux Spraying
Ultrasonic flux spraying, with its unique high-frequency vibration atomization technology, offers unparalleled advantages over traditional spraying. Using high-frequency vibrations of 20-150kHz, it evenly atomizes the flux into tiny droplets of 5-50 microns. The coating thickness can be precisely controlled to 0.1-10 microns, eliminating accumulation and leaks. This effectively avoids residual flux caused by excess flux and cold solder joints caused by insufficient flux.
Material utilization rates exceed 90%, far exceeding the 30%-50% rate of traditional air spraying, significantly reducing flux waste and production costs. It is compatible with various fluxes, including water-soluble and rosin-based fluxes, and is compatible with various substrates, including PCBs and chip pins. The spraying process is free of high-speed airflow impact, preventing displacement or damage to delicate components.
Furthermore, the atomization process produces no bubbles, resulting in strong coating adhesion and even coverage of complex surfaces. It also reduces flux volatilization and lowers VOC emissions in the workshop. This combines process stability, environmental friendliness, and high efficiency, making it widely applicable to precision soldering applications in electronics manufacturing.
Flux Selection:
Flux Activity: The activity of the flux determines its ability to remove oxides from the solder joint. For soldering materials with a high degree of oxidation, a more active flux is required. For materials prone to corrosion, a less active flux is recommended to avoid excessive corrosion.
Flux Viscosity: Viscosity affects the spraying quality and fluidity of the flux. Flux with a higher viscosity requires greater pressure during spraying, but adheres better to the solder joint and is less likely to bleed. Flux with a lower viscosity is easier to spray, but may suffer from uneven distribution during soldering due to excessive fluidity. Therefore, it is important to select a flux with the appropriate viscosity based on the requirements of the spraying equipment and soldering process.
Ingredients of flux: The ingredients of flux should meet environmental protection requirements. Try to choose halogen-free and low-solid content flux to reduce pollution to the environment and corrosion to welding equipment.
Quality Control:
Spray Uniformity Inspection: The coverage and uniformity of the flux on the weld surface can be checked visually or microscopically. If uneven spraying is observed, the spray equipment parameters should be adjusted or components such as the nozzle should be replaced.
Controlling Flux Residue: Excessive flux residue can affect weld quality and may cause problems such as short circuits. Therefore, the amount of flux applied should be controlled to ensure that the residual flux on the weld surface remains within a reasonable range.
Welding Quality Inspection: After spraying flux, a welding test should be performed to verify that the weld quality meets the requirements. If poor weld quality is observed, the cause should be analyzed. Possible causes include improper flux selection, improper spraying process parameter settings, and appropriate measures should be taken to improve the weld.
About Cheersonic
Cheersonic is the leading developer and manufacturer of ultrasonic coating systems for applying precise, thin film coatings to protect, strengthen or smooth surfaces on parts and components for the microelectronics/electronics, alternative energy, medical and industrial markets, including specialized glass applications in construction and automotive.
Our coating solutions are environmentally-friendly, efficient and highly reliable, and enable dramatic reductions in overspray, savings in raw material, water and energy usage and provide improved process repeatability, transfer efficiency, high uniformity and reduced emissions.
Chinese Website: Cheersonic Provides Professional Coating Solutions
