Welding Head

Welding Head/ wire bonder (Hot Press precise welding machine)  

Manufacturer: AVIO
Model: NA-62D
Location: SE1 154 (Cleanroom)

For making bonds between two electrodes. Precision “Parallel-gap” type series welds where the electrode gaps are small and must be rigorously controlled.

Wire Bonder / Welding Head — AVIO NA-62D Parallel-Gap Welder

The AVIO NA-62D Wire Bonder (Hot Press Precision Welding Machine) is a parallel-gap resistance welding system designed for making precise electrical connections between microelectronic electrodes. It is commonly used in cleanroom environments for fine-scale bonding where electrode spacing and weld quality must be tightly controlled.

Key Features

  • Parallel-gap resistance welding for micro-scale bonding
  • High precision control of electrode gap and weld parameters
  • Stable and repeatable weld formation
  • Suitable for fine wires, thin films, and microelectrodes
  • Cleanroom-compatible operation

Operating Principle

  • Two closely spaced electrodes apply pressure to the contact region
  • A controlled current pulse passes through the material
  • Localized resistive heating forms a weld between contact points
  • Precise gap control ensures uniform energy delivery and bond quality

Operation Workflow

  • Position electrodes and align bonding area
  • Set welding parameters (current, force, pulse duration)
  • Bring electrodes into controlled contact
  • Apply welding pulse to form bond
  • Inspect bond quality under microscope

Applications

  • Bonding between microelectrodes and contact pads
  • Interconnection of fabricated devices
  • Packaging and device assembly in cleanroom
  • Repair or reinforcement of electrical connections

Training and Usage

Users are trained on:

  • Electrode alignment and gap control
  • Parameter optimization for different materials
  • Safe operation of welding current systems
  • Inspection of bond integrity and quality

⚠️ Safety Considerations — AVIO NA-62D Wire Bonder / Welding Head

Electrical Safety

  • High current pulses are used for welding—avoid contact with electrodes during operation
  • Ensure proper grounding and do not operate with exposed wiring
  • Power must be OFF before adjusting electrodes or performing maintenance

Thermal Hazards

  • Localized heating occurs at the weld  components may remain hot after bonding
  • Avoid direct contact with recently welded areas
  • Allow sufficient cooling time before handling samples

Mechanical Hazards

  • Moving electrodes can pinch or crush fingers
  • Keep hands clear during electrode engagement
  • Use proper tools for alignment and positioning

Eye and Face Protection

  • Use safety glasses at all times
  • Avoid looking directly at the weld point during operation (sparks/flash may occur)

Material Safety

  • Some materials may release fumes during welding
  • Ensure adequate ventilation or use under appropriate exhaust conditions
  • Handle contaminated or coated samples according to cleanroom protocols

Cleanroom Safety

  • Operate only after proper training and authorization
  • Maintain tool cleanliness to avoid contamination
  • Use appropriate PPE (gloves, gowning)

Detailed Safety Considerations – Welding Head / Parallel-Gap Welder (AVIO NA-62D)

The parallel-gap welding system involves hazards related to high current electrical pulses, localized heating, mechanical movement, and material interaction during welding. Improper operation can result in electrical shock, burns, pinch injuries, equipment damage, and compromised bond quality. Only trained and authorized users may operate the system.

Electrical and High-Current Safety

  • The system uses high current pulses to generate localized resistive heating for welding.
  • Never touch electrodes or contact area during operation
  • Ensure proper grounding before powering the system
  • Do not operate with exposed wiring or damaged cables
  • Always turn OFF power before adjusting electrodes or performing maintenance
  • Avoid contact with conductive parts during active welding

Thermal and Burn Hazards

  • The welding process produces localized high temperatures at the bonding interface.
  • Do not touch welded areas immediately after operation
  • Allow sufficient cooling time before handling samples
  • Use tweezers or appropriate tools for handling bonded components
  • Be aware that small structures can retain heat longer than expected

Mechanical and Pinch Hazards

  • The system includes moving electrodes and pressure mechanisms.
  • Keep hands clear of electrode region during operation
  • Avoid placing fingers near the contact point during alignment
  • Use proper tools for positioning and alignment
  • Ensure stable sample placement before initiating weld

Arc/Flash and Eye Safety

  • Welding may produce sparks, flashes, or bright emission.
  • Wear safety glasses at all times
  • Avoid direct viewing of the weld zone during operation
  • Ensure proper lighting and microscope use for alignment rather than direct viewing

Material and Fume Safety

  • Certain materials may release fumes or particulates during welding.
  • Use only approved materials compatible with the system
  • Ensure adequate ventilation or local exhaust is available
  • Avoid inhalation of fumes from heated or coated materials
  • Handle contaminated or coated samples according to cleanroom protocols

Process Parameter Safety

  • Incorrect welding parameters can damage the sample or equipment.
  • Set current, force, and pulse duration within recommended limits
  • Start with conservative parameters and optimize gradually
  • Avoid excessive current or pressure that may damage electrodes or substrates
  • Monitor weld quality and stop if irregular behavior occurs

Electrode Handling and Alignment Safety

  • Precise electrode positioning is critical for safe and effective operation.
  • Do not touch electrode tips directly
  • Ensure electrodes are properly aligned before welding
  • Avoid excessive force during alignment adjustments
  • Inspect electrodes regularly for wear or damage

Contamination Control

  • Clean conditions are critical for reliable bonding.
  • Use clean, approved samples and materials
  • Avoid introducing debris, oils, or residues into the welding area
  • Clean electrode tips and stage as required
  • Prevent cross-contamination between different materials

PPE Requirements

  • Cleanroom garments (as required for the area)
  • Safety glasses (mandatory during operation)
  • Gloves when handling samples and components

Operational Safety Checks (Pre-Run)

  • Electrodes are properly aligned and undamaged
  • Sample is securely positioned
  • Welding parameters (current, force, pulse) are correctly set
  • System grounding and electrical connections are verified
  • Work area is clear of obstructions
  • Ventilation/exhaust is available if needed

Post-Operation Safety

  • Turn off power before making adjustments
  • Allow welded components to cool
  • Remove samples using appropriate tools
  • Inspect electrode condition
  • Clean workspace and remove debris
  • Log system usage and report abnormalities

Waste Handling and Contamination Control

  • Dispose of wire scraps, debris, and contaminated materials in designated containers
  • Do not leave residues on stage or electrode area
  • Maintain clean working conditions

Emergency Procedures

  • Electrical fault → shut down system immediately and notify staff
  • Overheating or burn hazard → stop operation and allow cooling
  • Electrode malfunction or misalignment → stop and report
  • Excessive sparks or abnormal welding → stop operation immediately
  • Exposure incident → follow cleanroom emergency procedures
  • Do not resume operation until the system has been inspected and cleared.

General Cleanroom Conduct

  • Use only approved materials and processes
  • Maintain precise alignment and cleanliness
  • Avoid unnecessary adjustments or force
  • Report equipment issues promptly
  • Follow all cleanroom safety and operational protocols