以及应用科学 Today and applied science
我将向你们展示超声波焊接技术 I'm gonna show you this technique of ultrasonic soldering
可以将各种不寻常的金属和非金属结合，如铜和硅 This let's you bond all kinds of unusual metals to non metals such as copper to silicon
铝镍磷 or aluminum to nickel or phosphor
铜与玻璃 bronze to glass
任何合格的金属，陶瓷或玻璃都可以 Pretty much any reasonable metal or ceramic or glass can be bonded with this technique
所以在今天的视频中 So in today's video
我将向你们展示它的工作原理 I'm gonna show you how this works
背后的科学原理 the science behind it
你可以自己做一个装置 how you can build your own rig
还有一些商用设备的选择 and then also some options for commercial equipment
所以要想成功 So to make this work
你需要两样东西 you need two things
一，超声波烙铁 One, the ultrasonic soldering iron
这其实很容易组装，你可以马上 And this is actually relatively easy to build with parts you can get uh right away
你可以在商业上买，但我们稍后会拆开看看我是怎么做的 And you can buy it commercially to but we'll take this apart later and see exactly how I built it
接下来你需要的是一种特殊的 And then the next thing you need is this special sorta
整个过程是活性萨达和基础材料的化学反应 This whole process is a chemical reaction between an active sada and the base materials
所以它完全不适用于普通的 So it completely doesn't work with just normal you know
电子产品订单，或其他种类的人造剑 electronics order, or really any other kind of sada that you might encounter um these active sword as are only made by two or three manufacturers worldwide
据我所知 And as far as I can tell
他们不使用经销商 they don't use distributors
所以你永远找不到这些分类机 And so you'll never find these sorters on
或者其他容易买到的地方 digit key or any other easy to buy a place
所以你要做的就是登录制造商网站 So what you have to do is go to the manufacturers website and it says
打电话询问更多细节 you know call us for more details
那么 So
每当我看到这个 whenever I see that
我总觉得这是个很好的提示 I always feel like that's a good prompt to kind of come up with an alternative
所以我今天大部分实验都用这个 So I use this for most of the experiments today
这其实是我在真空感应炉中融化原料，制成的合金 And this is actually an alloy that I made myself by melting down the ingredients in a vacuum induction furnace
然后倒出来，切成条。 and then poured it out and cut it into strips.
我们将在下一个视频中讨论这个问题 So that's we'll talk about that in my next video
但不管是钱，关系还是决心 But whether it's through money or connections or determination
你必须想出一些积极的莎达 you have to come up with some of this active sada
让我们先看看化学反应，看看这个过程和普通焊接有什么不同 So let's uh look at the chemistry first and see how this process is so different from regular soldering
所以在传统焊接中 So in conventional soldering
我们要找的是一种金属对金属的结合 what we're looking for is a metal to metal bond
这很好，因为所有的金属 And this is good because all metals
据我所知 as far as I know
用这种金属键 use this metallic bonding
或者说是电子海 Or it's the sea of electrons
所以基本上，如果你 So basically, if you get
把金属放在一起加热 any metals next to each other and you warm them up a bit
它们会结合在一起 they will bond together
问题是 The problem is that
我们生活在氧气环境中。所以如果有一块金属 we live in an oxygen atmosphere here. So if you have a metal laying out
表面不是铜。 the surface here is not copper.
它其实是氧化铜，因为它在空气中停留了一段时间 It's actually copper oxide because this thing's been sitting out in the air for a while
这就有问题了，因为氧化铜会在萨德和基底金属之间 And So that's a problem because this copper oxide gets between the sada and the base metal
那不是金属 And that's not a metal
所以这种金属键就不能起作用 So then this metallic bonding can't work
熔剂的作用是去除氧化层，金属与金属接触 So the whole point of flux is that we remove the oxide layer and then we have metal to metal contact
熔剂也产生了这个小气泡 And then the flux also creates this little bubble
就像密封接头，这样你工作时氧气就进不去了 like literally an encapsulation of the joint so that oxygen can't get in there while you're working
这很有效 And this works very well
你知道有个笑话说 You Know The joke goes
刚开始焊接的人和专业人士有什么区别 what's the difference between someone just beginning soldering and a PRO
通量 flux
没错，你得用很多助燃剂，用对助燃剂 And it's true you got to use lots of flux and use the right kind of flux
这就是焊接在大气中工作的原因。 And that's what makes soldering work in atmosphere.
你知道，如果你不在金属表面清除特定类型的焊剂 One thing that I always found paradoxical is that you know if you don't clean certain types of flux off the metal after you're done with it
实际上会导致金属腐蚀 it will actually cause the metal to corrode
那么助燃剂是如何去除腐蚀 So how could it be that flux removes corrosion and then also causes it
答案是，正是氧化皮阻止了铜像铁一样聚在一起 The answer is that uh the skin of oxide is actually what's preventing this copper from crowding away like iron
所以如果你有铁 So if you have iron
它在生锈和分解的过程中基本上会剥落 it basically flakes apart as it rusts and disintegrates
但铜线没有，因为上面的编码是连续的 But copper doesn't do that because the coding on here is continuous and it actually uh protects the metal
所以如果我们把这些流入 So if we covered this influx
首先我们要消除氧化涂层 the first thing would happen is we eliminate the oxide coating
现在我们有了新鲜的金属 and now we have nice fresh metal
容易焊接 easy to solder
但如果我们把焊剂留在上面 But then if we leave the flux on there
这种编码无法再保护金属 that coding is no longer available to protect the metal
随着氧气扩散 So then as the oxygen diffuses in
它会腐蚀金属 it will corrode the metal
然后焊剂会去除氧化铁 And then the flux removes that oxide
然后更多的氧气进入并腐蚀它 And then more oxygen gets in and corrodes it
与直觉相反 So counter intuitively
腐蚀性很强 it's corrosive
同时去除腐蚀 And it removes corrosion at the same time
好 啊 Ok
这有助于金属间的结合 So that's good for metal to metal bonding
或焊接到反应性极强的金属上 But what happens if we want to sada to something that isn't metal or we want to solder to a metal that is so reactive that we can't come up with a chemical flux that works at reasonable temperatures
比如， Like,
比如说，钛 let's say, titanium
众所周知，钛很难结合，因为它非常活跃 for example, titanium is notoriously difficult to bond because it's so incredibly active
那我们怎么办？然后呢？我们采用主动焊接技术。 Then what do we do? Then? We go to this active soldering technique.
当使用活性萨达时 When using an active sada
没有焊剂 there is no flux
所以与其试图消除材料中的氧 And so instead of trying to eliminate the oxides that are present on the materials here
我们要在成分和溶剂之间进行化学反应 we're actually going to use a chemical reaction between the ingredients and the flux on whatever oxides are present
所以如果我们观察这些成分 And So if we look at the ingredients
它们其实非常相似 they're actually very similar
所以前三种成分是一样的 So the first three ingredients are the same
锡，银，铜是当今常用的无铅焊料 Tin, silver, and copper is what's very commonly used as a um a lead free solder these days
囊是c sac s a c
而活性萨达几乎和 and the active sada has almost the same thing
但对它来说 But to it
我们加入钛，大约百分之几，然后加入少量的 we add titanium at about a couple percent and then just a tiny tiny amount of syriam and gallium
这些其他成分的目的是使剑和非金属结合 And the purpose of these other ingredients is to make the sword a bond to things that aren't necessarily metals
比如说 So for example
钛，正如我之前提到的 the titanium, as I mentioned
非常活泼 is super reactive
如果我们在萨达中放一点 So if we put a little bit of that in the sada
萨达可以粘在非金属物体上 then the sada is able to stick to things that aren't metals because
在某种程度上 it in part
会形成这种氧化钛结构，能和非金属结合 um will create these titanium oxide type structures that can bond to um non metals
我们需要超声波机械能的原因是，表面婚礼仍然是个问题 The reason that we need the ultrasonic mechanical energy is because the surface wedding is still a problem
即使化学能将金属上的两层非金属或氧化层 Even if the sorta is chemically able to bond two non metals or oxide layers that are on metals
呃，有时候，呃，表面张力还是很高，以至于分子接触不到表面 um sometimes the uh surface tension is still so high that the sorta can't really get into like molecular contact with the surface
所以这种超声波能量基本上就是 And So this ultrasonic energy basically just bashes stuff around
增加了表面接触，直到它开始形成化学键 It increases the surface contact until the sorta can start making chemical bonds there
我在网上看过很多关于这个过程的图表 Um In a lot of the diagrams that i've seen online describing this process
这里显示了一种反应层 they show this kind of reaction layer here
所以焊点里可能有纯金属 So there might be pure metal inside the solder blob
如果你的碱基 And if your bases
玻璃，陶瓷之类的 glass or ceramic or something, there's this
有非金属和金属特性的化合物 into metallic region here where we have compounds that have properties of both the non metal and the metal and form this bridge between
我提到过钛是因为它对氧气有很强的亲和力 So I mentioned titanium is used because it has such a strong affinity to react with oxygen
事实上，它有点太强了 In fact, it turns out it's a little too strong
如果在焊料中加入钛，有时会将新的钛块扯开 What ends up happening is if we have titanium in our blob of solder and we've got the ultra sonics on so that occasionally it will sort of rip the blob open in such a way that fresh titanium is exposed to the joint
不幸的是，空气中到处都是氧气 Unfortunately, there's still oxygen everywhere because this is all happening in air
而在低温下，钛会氧化 And what would happen at low temperatures is the titanium would just oxidize
所以它把剑撕开了 So it ripped the sword a blow open
钛会被大气中的氧气氧化 The titanium would oxidize just with atmospheric oxygen
这样我们就没机会和表面结合了 And then we wouldn't really have a chance to bond with the surface
我们真正需要的是 What we really need is
这样它就能和表面的氧结合，形成良好的结合 unreacted titanium in contact with the surface so that it can bond with whatever oxides are going on with the surface here and give us a a decent bond
一些其他的成分可以解决这个问题。 So a couple of these other ingredients help with that problem.
西兰酒也很活跃 The syriam is also quite active
它在萨达星富含钛的颗粒周围形成保护泡 and it somehow forms a protective bubble around these titanium rich grains in the sada
这是相当先进的冶金技术 Um It's fairly advanced metallurgy
我会链接一些有趣的论文 And i'll link to some of the interesting papers here
锡拉姆和钛的浓度并不是恒定的 The concentration of syriam and titanium is not constant throughout the blob of sada
钛形成了这些颗粒，比如萨德中富含钛的区域， The titanium forms these grains like titanium enriched areas of the sada,
所以当你把其中一个东西撕开的时候 uh which is why when you rip one of these things open
你会看到新的钛 you get fresh titanium exposed
但很显然，雪利安也起到保护层的作用 But apparently, the syriam also interacts with these blabs and acts like a protective layer to keep the oxygen from getting in pretty advanced stuff
据我所知， As far as I can tell, this,
化学大约是10，20，30年前才发明的。 chemistry was only invented maybe 10 or 20 or 30 years ago or something.
所以在焊接方面，这是一项相对新的技术。 So it's a relatively new technology when it comes to soldering.
最后 And then finally
镓是一种表面婚礼剂 the gallium is a surface wedding agent
为了让所有东西都能相互接触 Again, just to help everything get in contact with each other
最后我要指出化学成分，镓 One last thing i'll point out with the chemistry uh gallium
纯镓和纯印第安能让非金属充分湿润 pure gallium and pure Indian can wet non metals just fine
事实上，如果你把它们放在玻璃上加热 In fact, if you put them on glass and warm it up
他们绝对能把玻璃弄湿 they will absolutely wet the glass just fine
所以它们不能被认为是纯剑的活性剑 So they can't be considered active sword as in their pure form
甚至可以这样使用 and even used that way just fine
唯一的问题是镓的熔点太低了 The only problem is the melting point of gallium is way too low
如果你拿着这个 If you hold this in your hand
即使它变成液体 even it turns to a liquid
而锇的熔点也很低 And the melting point of indium is also kind of low
所以你需要加点什么来提高熔点 And so you need to add something to it to raise the melting point
得到一个像铅或锡之类的 to get a practical sada like lead or tin or something
当你这么做的时候 And when you do that
它不再活跃了 uh it's not as active anymore
那么 So
你费这么大劲制造这些化学物质，是为了达到熔点 the reason that you go through the trouble of having all this chemistry is to get the melting point
你需要焊料的强度 You want the strength of the solder
你想让它和金属或非金属结合时具有侵略性 You want um the the aggressiveness in sort of bonding to the surface and the ability to to bond to metals as well as non metals
我们把焊枪拆开，你就知道怎么做了 Let's take apart this soldering gun so you can see how to build one of these
基本思想是我们要让这里更热 The basic idea is that we want it hotter here
当然，我们还希望里面有超声波能量 Of Course And we want there to be ultrasonic energy directed in there
但我们不能加热传感器，因为一旦到达居里点 But we can't heat up the transducer because that might you know hurt the transducer if we get up to the curie point or whatever
所以我们想要的是一根长金属棒，穿过铁条，分散足够的热量 So what we want is basically a long metal rod that connects that goes all the way through the iron and dissipates enough heat
当它到达这里的传感器时 By the time it gets to the transducer up here
我看了一张商业模型的图片就想出了这个设计 and I basically came up with this design after just looking at a picture of one of the commercial models
它可能会有很大的改进 um it could stand to have quite a bit of improvement
所以当我们把它拆开，我会解释我从中学到了什么。 So as we take it apart, i'll explain what i've learned from this thing.
当然。 Sure.
可以 Okay
所以我想找一种不适合热导体的金属 So I wanted a metal here that wasn't a good thermal conductor
所以我用了一块不锈钢 So I used a piece of stainless steel and then um
银剑插在螺纹棒上，丝入传感器 silver sword at it into a threaded rod that threaded in and bolted into the transducer
然后把银剑插在铁头上 and then um also silver sword at it to the existing tip of the of the iron
所以我其实是通过 So I actually made this thing by
休斯敦大学 uh
拆开 taking apart
廉价烙铁 a cheapo soldering iron
我用加热元件和这个铁片的尖端 And I used the heating element and the tip from this this exact iron
这就是它的样子 And So this is actually what it looked like
新的时候。 when it was new.
如你所见 As you can see
尖端有大量的侵蚀 there's actually a tremendous amount of erosion on the tip here
我只用这东西 I've only used this thing for
一下午的胡闹 an afternoon of horsing around
尖头完全不见了 And the tip is completely gone
所以我不太确定是怎么回事 So I'm not really sure what's going on there
可能是超声波能量太强了 Uh It might be a little too much or a lot too much ultrasonic energy
或者萨达的腐蚀性超乎我的预料 Or perhaps the sada is very corrosive in a way that I didn't anticipate
又或者尖端真的很糟糕 Or Or maybe the tip is just really that bad or something
但是 But
这是个未知数 that's one unknown
传感器确实太大了。 to it's absolutely true that this transducer is way too large.
所以这是 So this is
理论上，一个六十瓦的传感器和驱动 in theory, a 60 watt transducer and driver
我选它的唯一原因是它很容易买到 And the only reason I picked this is because it was easily available
我刚在易趣上买了传感器 I just went on ebay and got the transducer
司机 And the driver
不，40美元，50美元之类的。 for c no $40 or $50 or something like that.
但商用超声波烙铁通常在10到15瓦之间 But the commercial ultrasonic soldering irons are generally more in like the 10 to 15 watt range
就像你说的 And like you say
这是60 this is 60
所以我试着用一个非常棒的动作来把声音调小一点 So what I tried to do is use a very act to turn it down
但不幸的是，如果低于线电压的80%或90% But unfortunately, the circuit doesn't oscillate if you get it below about 80 or 90% of line voltage
所以它的运行速度接近60迈 So it's it is running it close to the full 60
那是什么 What's there
当然，我不想自己拿着金属，因为两者都有 And then of course I didn't want to hang onto the metal myself due to both
电击电位太高，抓不住。 shock potential and uh it's too hot to hang on to.
所以我做了这个玻璃纤维罩，这样我的手就不会被打了 So I made this fiber glass cover here so I could put my hand hand here without getting beaten up
加热元件 And the heating element is just
只是一根金属管，电线脱落了。 it's just a metal tube with the wires coming off.
在第一圈的时候我确实有点问题。 Now I actually did have a problem with this in the first rev.
我用了 Uh I used
最早的烙铁里。 in the in the original soldering iron.
它有弹性纤维玻璃保护器 It had these flexible fiber glass protectors
但不幸的是，超声波能量太强，以至于玻璃纤维里的电线 But unfortunately, the ultrasonic energy is so powerful that the wire inside the fiber glass rubs against the
轴在这里，最终烧穿。 the shaft here and eventually burns through.
我找到另一种烙铁，里面有硬陶瓷管绝缘体 Instead, I found another brand of soldering iron that has hard ceramic tube insulators in there
所以我把它掰成几块，用它来防止电线靠近中心杆 And So I just broke this into pieces and used this as the in slater to keep the wires away from the center rod
在我之后的冒险中 Later in my adventures
我拿到了一些商用莎达的样品 I was able to get a couple samples of commercially made active sada
这些是苏打灵魂186和297。 So these are soda souls, or 186 and 297.
这些其实是铅合金 And these are actually lead alloys
我把它们放在x-r-f枪下 Um And I put these under the x r f gun to determine what was inside their
结果出人意料地不确定 And the results were surprisingly inconclusive
我在这两种合金中都没找到钛 I did not find any titanium in either of these alloys
这一点也不奇怪，因为他们有锆 um which is not too surprising right off the bat because they had zirconium instead
根据我的研究 And based on my research
锆可以和钛一样活性 the zirconium could be as active as titanium and essentially substituted
但这只是很小的一部分 But it's a very small amount
在x-r-f枪的分析中，只有0.1%到2% just about point one or 2% on the x r f gun analysis
沙子 Sand
所以我有预感含铅的化学成分 So I have a feeling that the leaded chemistry is might be slightly different
尽管找了这么久 And despite all the searching
我找不到关于制造含铅活性焊料合金的信息 I couldn't find much information about making leaded um active solder alloys
通常，你知道电子产品的人喜欢让它订购，因为它更容易流动 And normally, you know electronics folks sometimes prefer let its order because it flows more easily
但在这种主动焊接中 But in this active soldering
根本没有流动这回事 there is no such thing as flowing
因为你必须有机械能之类的东西 Like you can't reflow these active sword as you have to have the mechanical energy and everything
这是个粗糙的过程 It's kind of a rough process
这几乎和 It's almost the opposite of
非常光滑，干净的电子焊接。 very smooth, clean electronic soldering.
那么 So
你知道，如果不需要流动，你就不需要更多的铅 you you know without the need to have the sort of flowing you don't really need led as much
我想这就是为什么我们关注的是无铅合金 And I think that's why the focus has been on lead free alloys
尤其是这种主动焊接 especially for this active soldering
总之，我想我们可以看一些特别相关的例子来结束这节课 So Anyway, so I thought we'd close by taking a look at some especially relevant examples of how you might use this in current technology
它的一个特别用途是与涂有I.t.o.涂层的玻璃结合 One especially relevant use of this is to bond to I t o coated glass
在这个例子中 So in this case, i've got
电路通过编码供能，通过玻璃上的I-t-o涂层 um the circuit powered through the coding through the I t o coating that's on the glass there
你可以看到a类在表面打磨得有多好 And you can see how nicely the sort a has whetted the surface
嗯 And Um
好处是，你可以用导电环氧树脂或物理夹 you know the benefit there is the only other way you could do this is pretty much with a conductive epoxy or maybe a physical clamp
但如果你的应用不允许物理钳制 But if your if your application doesn't allow physical clamping
那我认为你只是另一种用途 then I think you're only other application
或者你唯一的选择就是导电环氧树脂 Or your only other choices are conductive epoxy
这很好，因为它很快 So this is kind of nice because it's instant
它确实能给你一个高温键，比环氧树脂更牢固的键 And It does give you a pretty high temperature bond and a stronger bond than epoxy might
另一种用途是将铬或夜 Another application is to bond nye chrome or night
所有电线接到电路板上 and all wires to circuit boards
所以如果你想在你的项目里做一个微型加热器，或是一个形状记忆合金的实现器 So if you wanna do a tiny little Micro heater in your project or a shape memory alloy actuator in your project
通常要用钳子夹住那根不寻常的合金线 often connecting that uh unusual alloy wire to the circuit board is a problem you have to use clamping typically
这样有了活性萨达，你就能把它放上去了。 so the with the active sada, you can get it on there.
我已经和铬合金有了很好的化学反应 And i've had some pretty good bonds with nichrome
呃，我不认为热量会是个问题，因为某种合金会在，呃，周围融化 Um I don't think the heat would be a problem because the sorta alloy is gonna melt around um
200 200
但你可以让这些合金熔化到300度 But you can get these alloys that melt all the way up to 300
所以根据你的申请 So depending on your application
完全没问题 would be totally fine
同样的，焊接钨丝也很困难 Similarly, soldering tungsten wires is of course very difficult without this process
所以如果你的应用需要很强的强度 And so if your application needs a really high strength
非常细的钨丝是个不错的选择 very thin wire tungsten is a good choice
但通常情况下 But usually, again
你得夹住它 you have to clamp it
但是这个焊接过程可以解决这个问题 Um But this soldering process takes care of that
最后，你知道我玩这个的时候 And finally, you know I as I was playing around with this
我发誓我在石墨上做过这个 I could have sworn I had this work on graphite
如果你读过相关文献 And if you read in the literature
你会发现你可以做超声波检查 you will find some claims that you can do this ultrasound
在石墨上进行超声波焊接 or ultrasonic soldering process on graphite to bond
比如说铜和它之间的电连接 say copper to it for an electrical connection
我喜欢你说的，我做过这件事 And I like you say I had this thing work
不幸的是没有被拍到 unfortunately didn't get on camera
因为我已经试过很多次了 And since i've been trying it over and over
根本没用 it hasn't worked
所以我想我可能有一个机械装置 So I think I might have just had like a mechanical
它可能冻住了，卡在表面上了 like it probably froze and just locked into the surface features here or something
据我所知 As far as I can tell
我不能用我自己的合金或商用石墨 I can't get it to work on graphite with my own alloy or the commercial ones
类似的，我试过了，只是为了刺激聚合物 Similarly, I tried this just for kicks on polymers
我用过氨纶和尖峰塑料 I tried it on polyamide and peak plastic
当然它不会粘在 and of course it doesn't stick
所以基本上，它起作用了， So basically, it works on,
据我所知 as near as I can tell
所有金属和所有金属氧合物 all metals and all metal oxides is basically what this thing is best for bonding
是 啊。 Yeah.
我还在一个钛氮合金钻头上试过 I also tried it on this titanium nitride coated drill bit
它似乎能很好地粘住 And it seems to stick just fine
嗯 Um
我猜是氧化铁 so I guess metal oxides
还有其他的东西 night rides, and all the other stuff too
我还要指出，这只是把软锯 Um I should also point out this is just soft sawder
所以 And so
你知道你不会用这个做拖车钩的。 you know you're not gonna make a trailer hitch out of this.
如果你使劲拉，你会弄坏萨达的。 You're You're gonna break the sada if you pull hard enough.
它更适用于电气接触和轻型机械连接 Um It's meant more for electrical contact and light mechanical connections
但它的能力还是让人印象深刻 But it is still pretty impressive in what it can do
在我拍下一段视频之前 Okay, so before I make the next video
如果你想让我试试超声波技术是否管用 let me know if you want me to try something specific to see if this ultrasonic technical work
下节课我们会讲到感应炉和如何制造金属合金 And then next time we'll talk about the induction furnace and how to make metal alloys
好吧，我希望你觉得这很有趣 All right, well I hope you found that interesting
下次见 And I will see you next time
拜伊 Bye