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Microwelding is the precise placement of connective metals and energy to form welds less than 100 micrometres wide. Micro resistance welding is used to join flat sheets, micro flash welding is for small butt joints, micro arc welding is for any shape, and laser microwelding is used in automated industrial environments.
The term “microwelding” refers to the precise placement of connective metals and the application of energy to form welds less than 100 micrometres wide. Usually done under a microscope for accuracy, the actual welding process in some cases mimics regular welding exactly, just on a much smaller scale. In most high-volume industrial environments, microwelding is automated, requiring little operator skill, but some special or irregular welds require a highly skilled technician with a very steady hand. Because this is such a precise and complicated process involving specialized tools, most jobs are outsourced to specialists.
Micro resistance welding is the most basic method and is used to join flat sheets of various metals. The two plates are slightly overlapped and the welding electrodes are placed on both sides of the overlap. An electric current is applied to heat the molten metal and the electrodes channel this current from one to the other through the overlap. As the metal cools, it bonds together to form a permanent bond. The resistance method is used to join tiny seams where the joint needs to be perfectly flat, such as in medical implants.
Micro flash welding is used for small butt joints, such as wire or jewelry, and is done by heating the end of each piece with an electric current and bonding them together. The process produces a steep temperature gradient along the axis of the part, thus allowing a wide variety of materials and shapes to be joined without warping. The most versatile of all microwelding operations, it produces sparks, so it is not suitable for flammable or temperature sensitive materials.
Micro arc welding is used to join two parts of any shape together, usually with the help of a filler material which is placed along the weld site to act as a glue. An electric current is applied to an electrode driven along the weld site, which heats the base metal and filler metal until they mix to form a new metal. As the site cools down, the parts and the filler are inextricably combined. This method is used to make precise repairs in metal molds and tools, especially when the pieces have chipped or worn out and need to be rebuilt.
Laser microwelding is normally the one used in automated industrial environments. The laser can be as tightly controlled as necessary and can reach awkward spots that other welding methods cannot, heating the metal almost instantly and requiring no filler material or pressure to create the perfect joint every time. The laser method can also be used to engrave metals, although shiny surfaces may need to be pre-treated to avoid reflecting the laser light.
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