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Energy efficiency in thermal joining processes

机译：热连接过程中的能源效率

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Rising energy costs make energy efficiency a key topic of the future for different industrial production processes. Thermal joining is widely used in the production process and causes a lot of energy lost. Both weld seam and filler material have to be heated to temperatures higher than the melting point. During the process a high amount of heat conducts into the work piece. Process efficiency and decrease of the energy consumption can be achieved through decreasing of the process temperature and the weld metal volume, respectively. To achieve these goals, material and process developments have to be carried out. These can result energy savings up to 40% are established in laser and arc welding processes. Nanotechnology is an innovative means to reduce required energy for joining processes. High energy which is necessary in the joining area can be generated in milliseconds only by using nanostructured reactive foils. Furthermore, the process velocity can reach several m/s. Due to the size effect the melting temperature of nanoparticles decreases inversely proportional to the radius. Therefore Ag nanoparticles with a diameter of 10 nm melt at about 200°C which has to be compared to micro, meso or macro sized Ag particles melting at 960°C. Filler material manufacture based on this effect allows producing metallurgical joints at very low temperatures. After the joining process the size effect disappears. This means that the reflow temperature is equal to the macroscopic melting temperature. Material and process developments offer a wide variety of opportunities to reduce the energy consumption in thermal joining processes. Especially taking advantage of nano effects to decrease the process temperature and increase the process velocity has great potential for future applications.
机译：不断上升的能源成本使能效成为不同工业生产过程中未来的关键主题。热连接在生产过程中被广泛使用，并导致大量能量损失。焊缝和填充材料都必须加热到高于熔点的温度。在此过程中，大量的热量传导到工件中。可以分别通过降低过程温度和降低焊接金属量来实现过程效率和能耗的降低。为了实现这些目标，必须进行材料和工艺开发。在激光和电弧焊工艺中，这些方法可以节省多达40％的能源。纳米技术是减少连接过程所需能量的创新手段。仅通过使用纳米结构的反应性箔片，即可在几毫秒内产生连接区域所需的高能量。此外，处理速度可以达到几m / s。由于尺寸效应，纳米颗粒的熔融温度与半径成反比地降低。因此，具有10nm直径的Ag纳米颗粒在约200℃下熔融，这必须与在960℃下熔融的微米，中观或宏观Ag颗粒进行比较。基于这种效果的填充材料制造允许在非常低的温度下生产冶金接头。在加入过程之后，尺寸效果消失了。这意味着回流温度等于宏观熔化温度。材料和工艺的发展为降低热连接工艺的能耗提供了各种机会。特别是利用纳米效应来降低工艺温度并提高工艺速度，对于未来的应用具有巨大的潜力。

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