Treatment for ultrasonic welding
View Patent ↗A metal welding horn having tripartite ceramic coating on its welding horn tip.
1. An ultrasonic welding horn comprising:
a metal substrate having a bottom portion and a tip portion operatively configured to transmit ultrasonic energy;
wherein the tip portion is coated with a tripartite oxide-ceramic coating having a total thickness of about 10 microns to about 40 microns and comprising:
a metal oxide layer in contact with the metal tip portion;
a dense ceramic coating layer in contact with said metal oxide layer, the dense ceramic coating layer having a hardness of about 400 to about 2000 HV; and
a lenticular porous ceramic layer in contact with said dense ceramic layer.
2. An ultrasonic welding horn in accordance with claim 1 , wherein the metal of the metal substrate is aluminum, titanium, magnesium or an alloy thereof, or a combination thereof.
3. An ultrasonic welding horn in accordance with claim 1 , wherein the metal oxide layer comprises a thin layer providing molecular bonding between said metal and said dense ceramic layer.
4. An ultrasonic welding horn in accordance with claim 2 , wherein the dense ceramic coating layer comprises a densely fused ceramic structure.
5. An ultrasonic welding horn in accordance with claim 2 , wherein the lenticular porous ceramic coating layer has substantially uniformly distributed pores.
6. An ultrasonic welding horn in accordance with claim 5 , wherein the lenticular porous ceramic coating layer is impregnated with a material selected from the group consisting of polytetrafluoroethylene, silicon, copper, iron, zinc, magnesium, zirconium, and titanium.
7. An ultrasonic welding horn in accordance with claim 1 , wherein the lenticular porous ceramic coating layer contains pigment.
8. An ultrasonic welding horn in accordance with claim 1 , wherein the tripartite oxide-ceramic coating is created by pulsed-voltages of positive and negative polarity.
9. An ultrasonic welding horn in accordance with claim 1 , wherein the lenticular porous ceramic layer has a friction coefficient of less than 0.15 against steel.
10. An ultrasonic welding horn in accordance with claim 1 , wherein the tripartite oxide-ceramic coating comprises spinel and/or corundum.
11. A resonator comprising:
a top portion; and
an open bottom portion coated with a tripartite oxide-ceramic coating having a total thickness of about 10 microns to about 40 microns and comprising:
a light metal oxide coating layer;
a dense ceramic coating layer in contact with said metal oxide coating layer, the dense ceramic coating layer having a hardness of about 400 to about 2000 HV; and
a lenticular porous ceramic layer in contact with the dense ceramic layer.
12. A resonator in accordance with claim 11 , wherein further comprising a piezoelectric material between said top portion and said bottom portion.
13. A resonator in accordance with claim 11 , wherein the dense ceramic coating layer comprises a spinel and/or corundum.
14. A resonator in accordance with claim 13 , wherein the lenticular porous ceramic coating layer is modified with a coating substance.
15. A resonator in accordance with claim 14 , wherein the coating substance comprises PFTE, paint/pigment, or metal.
16. A resonator in accordance with claim 15 , wherein the metal comprises iron, copper, zinc, titanium, zirconium, or magnesium.
17. A resonator in accordance with claim 11 , wherein the resonator comprises a substrate material of aluminum, titanium, or magnesium.