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Kunshan Micro and Precision

Catalog

Company profile Work principle Cases sharing Summary

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Company profile

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01 Company profile

Core technology-  the most advanced diffusion welding

1.Our R&D team is composed by experienced experts, professors and returned oversea PhD.2.The strength of welded areas exceed 90% of the base material.3.Bonding location can achieve Level A1 mirror polishing.4.Realize different materials (e.g. copper+steel) connection.

Design and manufacture conformal cooling channel1.Our team leaded by a senior designer with 15 years tooling design experience.2.We offer optimized designed solution from cooling channel design to mold flow analysis and present it with DFM.3.We provide our customer with comprehensive service (from material preparation to diffusion bonding).4.Design solution can be customized to meet various customer requirements.

Target - To become a first-class professional manufacturer in the industry1.Specialize in and in-depth study of diffusion bonding.2.Being detail-oriented enable us to serve our customer with optimized design solution.3.To assist and support customer with comprehensive service. 4.High efficiency and high quality.

Work principle

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Solid-state joiningInitial state Connect the work piecesin solid state

Apply heat/ stressInitial plastic deformationRealize the dense connection of large area with tiny plastic deformationon the interface

Preserve heatInter diffusion and migration of atomAtom inter-diffusion on the interface and interface migration

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furnace mantle

 upper holder block

vacuum chamber

lower holder block

upper compression bar

work piece 1

work piece 2

lower compression bar

Organizational integrationDisappearance of interface and holesIntegration the work pieces with seamless connection

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02 Bonding test results-steel

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Tensile strength after welding is shown in blow pic.. The strength increase gradually from central area to outer-ring area. Break occurred when the tensile strength is around 800MPa~900MPa., which shows that joint strength is superior to those processed by heat treatment under the same condition.

2.Strength

After welding the sample hardness is around 35~40HRC, hardness of central area is slightly low, while the outer-ring area show high hardness

3.Hardness test1.Diffusion bonding can realize the material connect without defect2.The hardness and strength of welded joint can meet customer usage requirements3.The welded joint can go through heat treatment, such as quenching and tempering. 4.Diffusion bonding have no impact on material polishing performance

4.Conclusions

No visible defects or welding traces on the surfaces; after Metallographic etching, the bonding rate is 100% under 200x microscope, and no defect found.

1.Metallographic analysis

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2.Sampling Position

A "copper-steel" metallurgical diffusion bond zone with uniform width was formed at the interface, and intergranular diffusion of copper to steel occurred. The depth of the diffusion layer was measured to be about 10 microns. A "copper-steel" metallurgical diffusion bond zone with uniform width is formed at the interface. Intergranular diffusion of copper to steel has occurred. The depth of the diffusion layer is about 10 microns.

3.Metallographic analysis

1. Oxygen-free copper is tightly combined with die steel, without holes, cracks, and loose defects.2. The interface between stainless steel and oxygen-free copper has no physical defects such as microscopic voids and cracks.3. A "copper-steel" metallurgical diffusion bonding zone with uniform width is formed at the interface, and intergranular diffusion of copper to steel occurs. The depth of the diffusion layer is about 10 microns.

4.Conclusions

The test material is steel with length (50 mm), width (20 mm) and height (100 mm) ; And the copper with diameter of 6 mm. That make them bodning.It is processed to the level required by the process before bonding

1.Experimental methodTake the middle section of the welding block and observe the surface metallography and connection condition.

Bonding test results-different material

04 Technological process

Material preparation

Processing sheet

Bonding

Delivery

According to your material numbers that prepare base material

Manufacture according to your 3d drawing

The sheet is bonded as a whole

Normal manufacture

Cases sharing

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The product position is a two-way compound surface and the middle turning position is relatively weak. If the traditional waterway is used, the product surface cannot be effectively cooled. At the same time, the product is difficult to demold due to uneven cooling and the size is serious.

Reason

01 Conformal cooling-Copying case

01 Determination of design scheme9-layer cooling channel was designed base on the shape of the product, 11 sheets are needed.

02 Manufacturing and bondingBond the sheets into cooling channel.

03Machining shapePolishing the cooling channel accordingTo machining process.

04 Results1.Molding cycle was shorten 24%2.Production yield 15% improved3.Hook dimensions were in spec4.Product dimensions were well controlled.5.The appearance of the mirror is effectively guaranteed

Bonding location

Cosmetic surface is A1 mirror surface with high dimensional requirement for ultrasonic bonding traditional cooling channel can’t meet the requirements

Reason

02 Conformal cooling-high polish surface

01Design solution2-layers cooling channel was designed base on the shape of the product, 3 sheets are needed

02 BondingBond the sheets into cooling channel.

03 Machining processPolishing the cooling channel according To machining process.

04 Test result1.Surface finish meet A customer class A1 requirement.2.Good cooling effect , no taper issue.3.Better product appearance due to more even cooling temperature.

Bonding location

It’s very difficult to fill in the low flowability material with such labyrinth design.We designed multiply cooling channel with copper columns to provide balanced temperature and cooling effect to resolve this.

Reason

03 Conformal cooling-different material

01 Design solutionA 2-layers cooling channel was designed base on the shape of the product, 2 sheets and 100+ copper columns are needed.

02 Bonding

03 Machining processPolishing the cooling channel accordingTo machining process.

04 Test result1.Better material filling2.Product dimensions were improved and in spec.3.Production yield improved , production cycle shortened.Copper 

columns

04 Conformal cooling--circular cases

Entry point cooling Outline cooling Conformal insert

05 Conformal cooling --classic cases

Mold cavity lineament Laryngoscope slider The  thin-wall insert

06 Cnformal Cooling analysis

Before

After

The cooling speed is faster and more uniform after adding the conformal cooling, which plays a very obvious role in improving the surface quality of products and greatly compressing the whole molding cycle.

Conclusions

07 Cnformal Cooling analysis

Before

After

With the same C / T and mold temperature, the overall temperature of the product will be more uniform, which will greatly improve the deformation.

Conclusions

Summary

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Bonding strengthDiffusion welding is achieved through motion blending on the molecular level, so the mechanical properties of the welded interface are very close to the base metal.

The polishing performance of the welded interface is very close to the base metal.

Different materialsThe connection of copper and iron can be realized by diffusion welding, and the uniform cooling also facilitate accomplishment of flawless products

QualityConformal cooling channels can effectively wrap the surface of product which can help to prevent the negative impact of uneven cooling.

CostUniform cooling shorten the molding cycle and ensure the product profile, that help to the development cost and manufacturing cost

Cooling periodThe design and manufacture of cooling channel is based on the shape of the product which help to enhance the cooling effectiveness

Mirror surface

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Advantages of diffusion bondingServe the world with the best

technology

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