Automated alignment and welding of tungsten filaments with maximum process reliability
In microassembly, joining extremely thin, high-temperature-resistant filaments requires maximum control over positioning, energy input, and process stability. Our VersaWeld is designed to meet these requirements, enabling automated positioning and subsequent laser welding of tungsten filaments with diameters of approximately 30 µm.
Tungsten is characterized by a very high melting point of 3,422 °C, high rigidity, and low thermal expansion. These properties make the material mechanically stable but also difficult to join. When combined with steel or stainless steel, additional challenges arise due to widely differing melting points, thermal conductivities, and expansion coefficients. VersaWeld masters this dissimilar material combination through precisely dosed laser energy, minimal heat-affected zones, and high-precision active alignment, which defines the joining area in a stable and reproducible manner.
Active alignment enables electrically conductive contacting
Coiled tungsten filaments are fed from trays, aligned with steel contacts in a defined position using image processing technology, and welded in an argon atmosphere. Passive alignment ensures that reproducible, electrically conductive contacts are achieved.
The connection of tungsten, with a melting point of 3,422 °C, and stainless steel, with a melting point of around 1,450 °C, requires precisely controlled heat input to prevent uncontrolled melting of the individual materials. VersaWeld uses precisely defined laser parameters to minimize stress and crack formation due to different thermal expansion and to create strong, durable joints without compromising the wire geometry.
All process steps are performed fully automatically by VersaWeld and are completely documented. This ensures traceability, process reliability, and a robust basis for the subsequent manufacturing steps.
CTA: Learn more about our VersaWeld laser welding station here: VersaWeld - Nanosystec GmbH