Kulicke & Soffa has introduced ASTERION-TW, an ultrasonic terminal welding system for next-generation power module manufacturing, adding another solid-state interconnect option to its ASTERION platform.
The company says the system is designed for high-reliability applications in markets including transportation, renewable energy and data centers, where conventional mass-reflow processes can be limiting. ASTERION-TW uses ultrasonic welding rather than heat-based joining, and Kulicke & Soffa says that allows it to bond copper terminals up to 2 mm thick while avoiding external heat, adhesives, consumables and chemical byproducts.
On the motion side, the system includes a high-resolution linear motor positioning system with weld placement repeatability of ±40 µm (3σ). Kulicke & Soffa also says ASTERION-TW supports ±180° weld head rotation, a 150 mm vertical stroke for access into deep cavities, and a 300 mm x 300 mm work area. An optional material-handling package adds an inline pallet conveyor with high-force clamping and an integrated cleaning station.
Ultrasonic terminal welding is getting more attention in power electronics because it is a solid-state joining process. That means the materials are joined without melting the bulk interface the way reflow soldering does. In practice, that can help reduce thermal exposure, simplify the materials stack and make it easier to adapt interconnect schemes as module designs change. Kulicke & Soffa also says the process is a greener manufacturing option with lower energy consumption, zero emissions and improved recyclability of assembled components.
ASTERION-TW is the newest member of Kulicke & Soffa’s broader power interconnect lineup, which already includes AVALINE clip attach systems, the base ASTERION wire and ribbon wedge bonding platform, and ASTERION-PW for pin welding. “ASTERION-TW reflects our commitment to deliver high performance interconnect solutions through engineering excellence and close collaboration with our customers,” said Ivy Qin, General Manager of Ball & Wedge Bonding at Kulicke & Soffa.
Source: Kulicke & Soffa
