Targeted Application of Flux
Targeted Application of Flux – Ultrasonic Spray Fluxing – Cheersonic
In fields reliant on welding processes, such as electronics manufacturing and automotive parts processing, the precise application of flux directly determines welding quality and production efficiency. Ultrasonic spot spraying equipment, with its unique atomization principle and precise control capabilities, has become a core piece of equipment for upgrading flux spraying processes. It effectively solves the pain points of traditional spraying methods, such as material waste, uneven coating, and severe pollution, driving the welding process towards high efficiency, precision, and environmental friendliness.
The core working principle of ultrasonic spot spraying equipment is based on the atomization effect of high-frequency ultrasonic vibration. The equipment converts electrical energy into high-frequency mechanical vibration of 20kHz-120kHz through a piezoelectric transducer. This vibration is transmitted to a vibrating plate at the tip of the nozzle, causing the flux to form a uniform liquid film on the surface of the vibrating plate. Under the action of high-frequency shear force, the liquid film ruptures, atomizing into micron-sized uniform droplets of 5-50μm, which are then guided by directional airflow and precisely deposited on the welding area of the workpiece. This nozzle-less atomization design not only avoids the clogging problems of traditional nozzles but also allows for precise control of droplet size by adjusting the vibration frequency, enabling accurate coating thickness control from 10nm to 100μm, perfectly adapting to the welding process requirements of different workpieces.
Compared to traditional methods such as air pressure spraying, brushing, and dipping, ultrasonic spot spraying equipment exhibits significant advantages in flux spraying. Firstly, it offers high precision, achieving targeted spraying by pre-setting workpiece coordinates, avoiding flux contamination of non-soldering areas. This is particularly suitable for processing precision workpieces such as high-density PCBs and microelectronic components, effectively reducing welding defects such as bridging and cold solder joints. Secondly, it boasts extremely high material utilization. The atomized flux droplets are deposited in a directional manner, eliminating splashing and waste, achieving a utilization rate of over 90%. This saves 30%-50% of flux usage compared to traditional processes, significantly reducing production costs. Thirdly, the coating exhibits excellent uniformity, with droplet size uniformity exceeding 90%, forming a dense, defect-free film. This ensures the flux effectively removes the oxide film from the workpiece surface, enhancing the strength and sealing of the weld joint. Furthermore, the equipment employs a closed-loop spraying design, reducing the fugitive emissions of flux volatiles, meeting green production requirements, and minimizing health hazards to operators.
The equipment’s applications are widely covered in core fields such as electronics manufacturing, automotive, and aerospace. In PCBA processing in electronics manufacturing, it is suitable for flux spraying on high-density circuit boards such as 01005 micro-components and BGA precision packages, ensuring high soldering yield. In automotive electronics, it is used for pre-treatment of safety-critical components such as ECUs and sensors, meeting vibration and corrosion resistance requirements. In aerospace, it is compatible with the brazing process of precision aluminum components, ensuring joint reliability through uniform flux spraying. Simultaneously, the equipment possesses flexible process adaptability, allowing spraying parameters to be adjusted according to workpiece size and production cycle, meeting both small-batch laboratory trials and the continuous operation needs of large-scale industrial production lines.
Standardized operation and maintenance are crucial for ensuring efficient equipment operation. Before operation, ensure proper safety precautions are taken, wear protective gear, and ensure the operating area is well-ventilated. Check that the power and air supply connections are normal, and preset parameters such as ultrasonic frequency and spray flow rate according to the flux viscosity. During spraying, test sprays should be conducted to adjust the coating thickness and ensure uniform coverage. After spraying, promptly clean the storage tank and pipelines with a suitable solvent to prevent residual flux from hardening and clogging. In routine maintenance, nozzles should be disassembled and wiped periodically. For long-term inactivity, inject rust inhibitors for maintenance. Scientific maintenance can extend the equipment cleaning cycle to 3-5 times that of traditional equipment, reducing operating costs.
As industrial manufacturing upgrades towards precision and green processes, the application value of ultrasonic point-spraying equipment in flux spraying is becoming increasingly prominent. With precise point control, efficient material utilization, and stable process performance, it provides reliable support for welding process optimization in various industries, not only improving product welding quality but also promoting cost reduction, efficiency improvement, and environmental upgrades in the manufacturing process, becoming an indispensable key equipment in modern industrial welding processes.
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.
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