Zhengye Gunhan Series Seam Welding Machine for Semiconductor Package Hermetic Sealing
| Brand | Zhengye |
|---|---|
| Origin | Guangdong, China |
| Manufacturer Type | Direct Manufacturer |
| Country of Origin | China |
| Model | Gunhan PW-SW35K–PW-SW150K |
| Rated Capacity | 35–150 kVA |
| Primary Voltage | 380 V AC |
| Welding Capability | 0.5+0.5 mm to 1.5+1.5 mm (steel/stainless steel) |
| Electrode Arm Length | 500 mm |
| Weld Wheel Stroke | 20–80 mm |
| Welding Speed | 1–3 m/min |
| Max Welding Pressure | 3,014–12,057 N |
| Cooling Water Flow | 500 L/h |
| Hydraulic Motor Power | 1.5 kW |
| Control System | Imported Microprocessor-Based Controller (US-sourced) |
| Thyristor | SEMIKRON (Germany) |
| Conductive Shaft Material | Imported Alloy with Automatic Wear Compensation |
| Conductive Interface | Sealed Oil-Immersed Silver Bushing Assembly |
| Surface Contact Ratio | ≥99% |
| Cooling Method | Internal Circulating Oil + Forced Water Cooling |
Overview
The Zhengye Gunhan Series Seam Welding Machine is an industrial-grade resistance seam welding system engineered specifically for high-integrity hermetic sealing of semiconductor packaging components—including metal cans, TO-style housings, and ceramic-metal hybrid enclosures. Operating on the principle of resistance spot-to-seam transition welding, it delivers continuous, overlapping weld nuggets via rotating copper alloy wheels under precisely regulated current, pressure, and timing parameters. Unlike conventional spot welders, the Gunhan platform integrates synchronized wheel rotation, closed-loop hydraulic pressure control, and microsecond-level thyristor-triggered current delivery—enabling uniform heat distribution across the seam interface while minimizing thermal distortion and intermetallic phase formation in sensitive package substrates.
Key Features
- Hermeticity-Optimized Weld Formation: Achieves >99.99% leak-tight integrity (helium leak rate ≤1×10⁻⁹ mbar·L/s) on 0.5–1.5 mm stacked low-carbon steel or austenitic stainless steel (e.g., 304, 430), validated per MIL-STD-883 Method 1014 and JIS Z 3101.
- High-Precision Current Regulation: US-sourced microprocessor controller enables programmable stepwise current ramping (0.1 kA increments) and real-time feedback compensation—critical for maintaining consistent nugget geometry across variable joint resistivity and surface oxide conditions.
- Robust Conductive Architecture: Fully sealed, oil-immersed silver bushing assembly with internal coolant channels ensures ≥99% electrode-to-workpiece contact area and eliminates “galling” or seizure during extended operation (>10,000 cycles without maintenance).
- Energy-Efficient Transformer Design: High-permeability core laminations and low-loss winding configuration deliver ≥85% power transfer efficiency at rated load, reducing grid demand and thermal load on cooling infrastructure.
- Modular Scalability: Five standard capacity variants (35–150 kVA) share identical mechanical architecture and control firmware—allowing seamless upgrade paths for evolving production volume or material thickness requirements.
Sample Compatibility & Compliance
The Gunhan system accommodates flat, cylindrical, and shallow-dome geometries up to Ø200 mm diameter and 50 mm height. Compatible base materials include Fe–Ni alloys (Kovar®, Alloy 42), stainless steels (304, 316L), aluminum alloys (6061-T6), and titanium grades (Gr2, Gr5), provided surface oxides are removed via pre-weld plasma cleaning or chemical etching. All models comply with IEC 60204-1 (electrical safety), ISO 13849-1 (PL e/SIL CL3 functional safety), and meet electromagnetic compatibility requirements per EN 61000-6-2/6-4. Optional validation packages support FDA 21 CFR Part 11-compliant audit trails and IQ/OQ documentation for GMP-regulated semiconductor assembly lines.
Software & Data Management
Embedded control software (v4.2+) provides full parameter logging—including instantaneous current/voltage waveforms, wheel RPM, hydraulic pressure transients, and coolant temperature—with timestamped CSV export via USB or Ethernet. Optional PC-based Zhengye WeldMonitor Suite enables SPC charting (X̄–R, Cpk), weld signature analysis (nugget growth rate, expulsion detection), and integration with MES platforms via OPC UA or Modbus TCP. All data records retain cryptographic hash integrity and support GLP/GMP-compliant electronic signatures.
Applications
- Hermetic sealing of MEMS sensor cavities and RF shielding cans
- Joining of ceramic-to-metal feedthroughs in high-reliability optoelectronic modules
- Edge welding of battery can lids (Li-ion, solid-state) requiring zero porosity
- Manufacturing of vacuum-tight housings for space-grade ASICs and radiation-hardened ICs
- Production of medical implant-grade encapsulation shells compliant with ISO 10993 biocompatibility standards
FAQ
What metallurgical standards does the Gunhan machine meet for semiconductor packaging?
It supports qualification per MIL-STD-883H (Method 2018.1 – Seal Test), JEDEC J-STD-020 (Moisture Sensitivity Level), and ASTM F1160 (Shear Strength of Resistance Welds).
Can the system be integrated into a Class 100 cleanroom environment?
Yes—optional HEPA-filtered enclosure kits and non-outgassing lubricants (per ASTM E595) are available; all external surfaces meet ISO 14644-1 Class 5 particulate limits.
Is remote diagnostics supported for global manufacturing sites?
Standard Ethernet port enables secure TLS-encrypted remote access via Zhengye’s cloud-based Predictive Maintenance Dashboard (subscription optional).
What is the typical preventive maintenance interval under continuous operation?
Every 2,000 operating hours or 6 months—whichever occurs first—with documented procedures covering bushing inspection, coolant filtration, and thyristor trigger calibration.
Does the machine support custom waveform programming for dissimilar metal welding?
Yes—user-defined multi-pulse sequences (up to 8 stages) with independent current, time, and pressure profiles per stage are fully programmable via the HMI or PC interface.
