CVD Diamond Coated Ultrasonic Welding Tool
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Solution Overview
Problem
Existing ultrasonic welding tools with polycrystalline diamond (PCD) coatings are complex and costly to produce, and often experience undesirable adhesion between the tool and the component being welded, which affects durability and reliability.
Innovation Solution
A diamond coating produced by Chemical Vapor Deposition (CVD) with a thickness of 0.5 to 20 μm, characterized by the absence of a metal binder phase, internal stresses, and specific Raman peak shifts, is applied to the tool, enhancing durability and reducing adhesion. This coating is combined with a titanium or hard metal carrier body and intermediate coatings like TiC or chromium carbide to improve retention and thermal conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If PCD coating is used, then diamond coating is achieved, but production becomes complex and costly due to requiring carrier connection by soldering
Solution Approach 1:
The invention extracts the metal binder phase from the diamond coating structure, using solely bound-free diamond crystals without any metal matrix. This eliminates the need for separate carrier connection steps and soldering processes, directly resolving the contradiction between achieving reliable diamond coating and maintaining production simplicity.
Solution Approach 2:
The invention creates a composite structure of bound-free diamond crystals directly bonded to the carrier body, eliminating the need for intermediate metal binder layers. This composite approach achieves both the desired coating properties and simplified production by integrating the coating and substrate into a direct bond structure.
2Reliability
If PCD coating is used, then diamond coating is achieved, but adhesion between component and tool cannot be reliably avoided
Solution Approach 1:
By removing the metal binder phase entirely and using only bound-free diamond crystals, the invention eliminates the adhesive properties that metal binders possess. The purely diamond-based structure provides a non-stick surface that prevents unwanted adhesion between the tool and workpiece, while maintaining welding reliability.
Solution Approach 2:
The bound-free diamond crystal structure creates a surface with inherent micro-roughness and porosity at the crystal boundaries, which reduces contact area and adhesion forces between the tool and component. This porous-like structure prevents reliable adhesion while maintaining the coating's protective functions.
3Duration of action of stationary object
If diamond coating thickness is increased, then durability is improved, but production complexity and cost increase
Solution Approach 1:
The invention changes the fundamental parameters of the coating structure by using bound-free diamond crystals instead of PCD, enabling direct deposition onto the carrier body. This parameter change allows for controlled thickness variation from 0.5 to 20 μm without requiring complex multi-layer structures or intermediate carriers, achieving both durability and production simplicity.
Solution Approach 2:
The surface of the carrier body is preliminarily structured with grooves or channels before applying the diamond coating. This preliminary action allows the diamond coating to be applied directly in the desired thickness range while ensuring proper adhesion and stress distribution, eliminating the need for post-coating processing or complex carrier designs.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The CVD diamond coating significantly extends the tool's service life by withstanding thermal and mechanical stresses, reducing adhesion, and improving durability, while the internal stresses and thermal conductivity facilitate efficient heat dissipation and adhesion prevention.
Implementation Method 1
the diamond coating to be produced by means of CVD a method
Implementation Method 2
A high thermal conductivity contributes to the fact that the heat transferred from the component to the diamond coating is dissipated as quickly as possible to the carrier body
Data Source
AI summary
The invention relates to a tool for an ultrasonic welding device, wherein a contact face of a carrier body (1) produced from a metal facing a component to be welded is provided with a diamond coating (3). To improve the durability, it is proposed in accordance with the invention for the diamond coating to be produced by means of CVD methods and to have a thickness (D2) in the range from 0.5 to 20 μm.