Hermetically Welding Microwave Packages

Lasers can be used to produce hermetic welds in sensitive compoentry such as microwave packages

, sensors and relays. Hermetic seals prevent contaminants from reaching circuits and also trap high quality inert atmosphere inside the packages.

Delivering very low heat input, laser welds can be located close to polymer seals, glass-to-metal seals, soldered components and sensitive circuitry without causing damage.

When processing microwave packages, the alloy of choice is aluminium. It is easy to machine, lightweight and possesses the necessary electrical and thermal properties.

A 4047 alloy lid is typically laser welded to a 6061-T6 alloy base with a butt, lap or fillet joint. The 12% silicon-aluminum alloy 4047 can be fusion welded to the 6061 without cracking for a strong hermetic seal.

Unlike other electronic devices, the package around the active elements form part of the microwave circuit. As most microwave circuits involve expensive radar or communication systems, very reliable hermetic seals and high yields are needed.

The packaging must also be robust and capable of being opened and reworked when needed. For rework, an end mill can machine through the laser weld. Once repaired, another lid can be welded onto it. The number of repairs is virtually unlimited.

In some instances laser welding is required through the lid into the dividing labyrinth walls to isolate certain parts of the circuit.

Pulsed Nd: YAG lasers are a good choice for microwave package sealing. Their high peak powers and low heat input can handle all the different alloys and create a very stable process while maintaining deep penetrations.

Fibre optic beam delivery is most common for these parts because of the consistent focus spot size and top-hat energy distribution which helps with fillet and butt joints to fill any gaps. It also achieves a good metallurgical mixing of alloys.

Welding speeds are generally 150-300mm/min for aluminium alloys and up to five times faster than this for iron alloys. If needed, weld penetrations of over 1.5mm are possible.

by: JK laser

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