How to detect welding defect issues at low voltage contact
views：96
author：Hiwave
source：Hiwave
time：2025-03-20
catogory：Industry News
For signal switches, relays, contactors, and other types of electronic products, the welding quality of the contact switch contacts is the guarantee. At present, resis……
For signal switches, relays, contactors, and other types of electronic products, the welding quality of the contact switch contacts is the guarantee. At present, resistance brazing, flame brazing, and resistance spot welding processes are commonly adopted for silver contact welding tasks。
Because it is impossible to perfectly control factors such as welding current, welding time, electrode pressure, material properties, etc., welding process issues have become the primary cause of numerous defects in silver contact welding, such as slag inclusion, pits, cracks, burn-through, and others. Only by identifying and analyzing these defects can effective adjustments and optimizations be implemented for the welding process. Thus, defect detection for silver contact welding is an indispensable step.
The defect detection methods for silver contact welding are mainly categorized into machine vision inspection and manual inspection. With advancements in technology, currently, automated mechanical inspection equipment, such as acoustic scanning devices (ultrasonic scanning microscopes), and optical scanning devices (X-RAY), are being more widely applied. These devices provide more stable and accurate detection results compared to manual inspections, as they are not influenced by subjective factors. The efficiency and effectiveness of detection have greatly improved, leading to a reduction in labor costs and achieving better cost control.
Using acoustic scanning equipment as an example, with Hiwave scanning microscopes, we can directly visualize the images of the welding areas. Defect locations exhibit different imaging characteristics, enabling inspection personnel to acquire defect information through the software system. Voids, slag inclusion, cold solder joints, and other defects can be clearly annotated for failure analysis and both qualitative and quantitative testing. Manufacturers can utilize the analysis results to optimize the welding process, such as adjusting welding current and voltage, replacing welding equipment, or switching welding materials, thereby ensuring subsequent production efficiency and improving the yield rate.
