Soldering Glass And Titanium With Ultrasonic Energy

Ultrasonic soldering is a little-known technology that allows soldering together a variety of metals and ceramics that would not normally be possible. It requires a special ultrasonic soldering iron and solder that is not cheap or easy to get hold of, so [Ben Krasnow] of [Applied Science] made his own.

Ultrasonic soldering irons heat up like standard irons, but also require an ultrasonic transducer to create bonds to certain surfaces. [Ben] built one by silver soldering a piece of stainless steel rod (as a heat break) between the element of a standard iron and a transducer from an ultrasonic cleaner. He made his special active solder by melting all the ingredients in his vacuum induction furnace. It is similar to lead-free solder, but also contains titanium and small amounts of cerium and gallium. In the video below [Ben] goes into the working details of the technology and does some practical experimentation with various materials.

Ultrasonic soldering is used mainly for electrically bonding metals where clamping is not possible or convenient. The results are also not as neat and clean as with standard solder. We covered another DIY ultrasonic soldering iron before, but it doesn’t look like that one ever did any soldering.

Ultrasonic energy has several interesting mechanical applications that we’ve covered in the past, including ultrasonic cutting and ultrasonic welding.

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An Affordable Ultrasonic Soldering Iron

One of the most interesting facets of our community of hackers and makers comes from its never-ending capacity to experiment and to deliver new technologies and techniques. Ample demonstration of this came this morning, in the form of [Hunter Scott]’s project to create an ultrasonic soldering iron. This is a soldering technique in which the iron is subjected to ultrasonic vibrations which cavitate the surface of the materials to be soldered and remove any oxides which would impede the adhesion of the solder. In this way normally unsolderable materials such as stainless steel, aluminium, ceramic, or glass can be soldered without the need for flux or other specialist chemicals. Ultrasonic soldering has been an expensive business, and [Hunter]’s project aims to change that.

This iron takes the element and tip from a conventional mains-powered soldering iron and mounts it on the transducer from an ultrasonic cleaner. The transducer must be given an appropriate load which in the case of the cleaner is furnished by a water bath, or it will overheat and burn out. [Hunter]’s load is just a soldering iron element, so to prevent transducer meltdown he keeps the element powered continuously but the transducer on a momentary-action switch to ensure it only runs for the short time he’s soldering. The project is not quite finished so he’s yet to prove whether this approach will save his transducer, but we feel it’s an interesting enough idea to make it definitely worth following.

This is the first ultrasonic soldering project we’ve featured here at Hackaday. We have however had an ultrasonic plastic welder before, and an ultrasonic vapour polisher for 3D prints. It would be good to think this project could spark a raft of others that improve and refine DIY ultrasonic soldering designs.