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1 WEBER ULTRASONICS Page 1
2 WEBER ULTRASONICS WEBER ULTRASONICS Page 2
3 ULTRASONIC TECHNOLOGY BASICS» Sound is a pressure wave which propagates in elastic media such as gases, fluids and rigid bodies. p Sound wave Rarefaction» Ultrasound designates a frequency range above the human audible range (>20 khz).» Frequency range in industrial processes extends from 18 khz to 5 MHz. Compression t» Sound propagation in liquids relevant for ultrasonic cleaning. WEBER ULTRASONICS Page 3
4 BASICS CLEANING SYSTEM Voltage Power Curve Generator Electrical Energy Cavitation Oscillation 25kHz = 25,000 cycles/sec 40kHz = 40,000 cycles/sec 1MHz = 1,000,000 cycles/sec Mechanical Energy Sound Energy Transducer WEBER ULTRASONICS Page 4
5 BASICS CAVITATION Bubble cycle Cavitation effects depend on: 5000 C / 500 bar» Frequency» Pressure amplitude, Liquid Temperature and properties (Viscosity, Vapor pressure) WEBER ULTRASONICS Page 5
6 BASICS - CAVITATION: BUBBLE OSCILLATIONS Collapse Source: Matula, T. Philos. Trans. R. Soc. Ser. A 1999, 357, 225 Movie: 3. Physikalisches Institut, Universität Göttingen WEBER ULTRASONICS Page 6
7 ULTRASONIC TECHNOLOGY FREQUENCY Frequency Low High 25 khz 132 khz 1 MHz Cleaning Precision Contamination Size Big Particle Thick Small Particle Thin» The size of the cavitation bubble determines the amount of energy released, cavitation strength at implosion.» High cavitation strength can lead to part surface erosion RIGHT frequency selection is important. Cavitation Strength Strong Weak WEBER ULTRASONICS Page 7
8 SOUND FIELD DISTRIBUTION» Finite element simulation (FEM)» High frequency => Small wavelength» Standing wave pattern 40 khz 120 khz WEBER ULTRASONICS Page 8
9 BASICS - CAVITATION: CLEANING EFFECTS Cleaning of a glass substrate at 40 khz Source: 3. Physikalisches Institut der Universität Göttingen WEBER ULTRASONICS Page 9
10 PRECISION CLEANING: PRINCIPLE Cavitation Streaming profile Particle Acoustic streaming Mikro streaming F Ad Particle u H u Ak Substrate» Ultrasonics induces additional forces» Stable and transient cavitation» Microstreaming» Acoustic streaming» Laminar flow with (viscous) boundary layer» Hydrodynamic boundary layer δ H (>500 µm)» Acoustic boundary layer δ Ak (1 MHz: 0,56 µm)» Streaming without ultrasonics generates no forces on small particles! WEBER ULTRASONICS Page 10
11 ACOUSTIC STREAMING WEBER ULTRASONICS Page 11
12 RANGE OF PRODUCTS: ULTRASONIC TRANSDUCERS SONOPLATE Space-saving design due to fitting on outside of containers Frequency: 25, 30, 40, 80, 120, 132, 170, 192, 250 khz SONOPUSH MONO HD For the strictest demands and toughest applications even in continuous operation at temperatures of up to 95 C Frequency: 25, 30, 40 khz SONOPUSH MONO Ideal for vacuum and overpressure environments Frequency: 25, 30, 40 khz SONOSUB Long service life and extremely good sonic yield due to use of optimized piezo transducer elements Frequency: 25, 30, 40, 80, 120, 132, 170, 192, 250 khz SONOSUB Extremely low space requirement (35 mm width) Frequency: 40, 120 khz UMC PLATE Transducers available specifically matched to the respective cleaning task Frequency: 500 khz, 1 MHz Frequency range for precision cleaning applications: 120, 132, 170, 192, 250, 500 khz, 1 MHz WEBER ULTRASONICS Page 12
13 TRANSDUCER TECHNOLOGY Piezoelectric submersible / plate transducer» Double mass configuration» Frequency range (almost) free of choice» Power rating W / element» High efficiency up to 95 %» Multiple frequencies possible with one transducer» Standard frequencies: 25, 30, 40, 80, 120, 132, 170, 192 und 250 khz» Multifrequency transducer 25/50 khz und 40/80/120 khz Head mass (Al, Fe, Ti ) Piezoelectric Ceramic Electrical connection Tail mass Tensioning bolt WEBER ULTRASONICS Page 13
14 HIGH FREQUENCY TRANSDUCERS High frequency transducer (>300 khz)» Plate transducer» Piezoceramic plate bonded on membrane» Spezific power approx. 3 W/cm²» Cooling depending on power and duty cycle or application WEBER ULTRASONICS Page 14
15 SONIC DIGITAL ULTRASONIC GENERATORS» Constant power output with digital regulation between 10% and 100%» Interface for monitoring and controlling process-relevant functions» Modular design available» High efficiency low heat build-up» Optimised operational reliability» Standard frequencies: 25, 30, 40, 80, 120, 132, 170, 192 and 250 khz. Further frequencies available on request.» Twin and Multi: Two or three cleaning levels in a single system (25/50 khz or 40/80/120 khz) BASIC SONIC DIGITAL Module SONIC DIGITAL LC SONIC DIGITAL ULC PREMIUM SONIC DIGITAL Module SONIC DIGITAL LC SONIC DIGITAL ULC SONIC DIGITAL HS Front control panel Service unit WEBER ULTRASONICS Page 15
16 PRECISION CLEANING EQUIPMENT» Modules with 250 W and 500 W power output» Frequency range 500 khz and 1 MHz» Transducers designed specifically for the cleaning task WEBER ULTRASONICS Page 16
17 APPLICATIONS 25 khz and 40 khz 40 khz to 120 khz 250 khz to 1 MHz» Automotive industry» Manufacturing systems industry» Galvanic» Desintegration» etc.» Jewelry» Optics» Medicine» Elektronics» etc.» Semiconductors» Precision parts» Nanotechnology» Photovoltaics» etc. Increased requirements from e.g. optics, HDD, wafer industries WEBER ULTRASONICS Page 17
18 APPLICATION: PRINTED CIRCUIT MANUFACTURING Cleaning system Ultrasonic transducer Circuit board Transport roller» Cleaning of microvias (<100µm) before plating» Thin boards small roller distance» Frequency 120 khz» Solution: narrow transducers (35 mm) with laser-welded housing WEBER ULTRASONICS Page 18
19 CLEANING EFFICIENCY POWER SELECTION- Example: tank for precision parts Ultrasonic power: 600W Volume: 36 l Power density (volume related): 600W / 36l 17 W/l Caution: only coarse guidelines! Evaluation necessary! WEBER ULTRASONICS Page 19
20 APPLICATION EXAMPLE HARD DISK DRIVE CASE-» 2.5 HDD case part» Current machine with 58 khz» Evaluation with LPC (liquid particle count)» Requirement 1150k/part (particle<0,5µm)» Test with higher frequencies» LPC results in appr. 1350k/part» After retrofit with 132 khz: <850k 1350k WEBER ULTRASONICS Page 20
21 ELECTRONIC ASSEMBLY CLEANING» Damaged bond wires at 40 khz» No damage at 120 khz with cleanliness requirements accomplished 40 khz 120 khz WEBER ULTRASONICS Page 21
22 PRECISION OPTICS LED sapphire» Diameter up to 6» Frequency 1 MHz» Particle size 0.1 to 2 µm» Open tank design» Power density 15 to 20 W/l WEBER ULTRASONICS Page 22
23 MEASURING EQUIPMENT ULTRASONIC PARAMETERS» Local soundpressure measurement» Display in watts/liter or mv» No traceable calibration» Spatial averaging by moving the sensor through the tank» Large measurement uncertainty in practice» Cleaning indicators» Color change through cavitation» Removal of test contaminants» Cleaning of medical instruments WEBER ULTRASONICS Page 23
24 DETECTION OF CAVITATION ACTIVITY» Detection of cavitation noise» Correlation with aluminum foil tests» Display of cavitation noise figure» Calibrated hydrophones» Noise spatially independent» Currently no standardization» Application requires trained personal WEBER ULTRASONICS Page 24
25 WEBER ULTRASONICS Page 25
26 WIN EURASIA METALWORKING Weber Ultrasonics at WIN EURASIA: Hall 6 Booth C122 WEBER ULTRASONICS Page 26
associates Precision Cleaning Systems 3678 Bassett St., Santa Clara CA 95054 Phn: [ 408 ] 727 8388 Fax: [ 408 ] 727 8991 E-Mail tony@tmasc.
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associates Precision Cleaning Systems www.tmasc.com 3678 Bassett St., Santa Clara CA 95054 Phn: [ 408 ] 727 8388 Fax: [ 408 ] 727 8991 E-Mail tony@tmasc.com Basic Facts on Ultrasonic Cleaning Process Description
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