Abstract: Full life cycle continuous welding and phased welding experiments were carried out on micro-resistance spot welding electrodes under unipolar and bipolar heating modes, respectively, in order to elucidate the effect of heating mode on the burning behavior of electrodes and the performance of welding joints in the Cu-Al wire bonding process of microelectronic packaging. The burning loss law of the electrodes under different heating modes during the continuous welding process was elaborated based on the electrical, thermal, and geometric physical properties of the electrodes during the experimental process, as well as the morphology and tensile shear force of the welded joints. It was studied how the performance of the welded joints under different heating modes was affected by electrode burning loss. Analyses were conducted on the electrode failure mechanisms under different heating conditions. The results demonstrate that the bipolar heating mode can effectively prolong increase the electrode service life and tensile share strength, surface quality, of welded joints. The electrode shows three distinct phases of continuous burning loss over the course of its life cycle under both heating modes: initial, stable, and severe burning loss. In comparison to unipolar heating mode, bipolar heating mode reduces the degree of electrode burning loss during each welding stage. The primary forms of electrode failure in both heating modes include fatigue cracks, surface peeling, droplet sputtering, recrystallization, grain development, and melting. The primary causes of electrode failure are high temperature oxidation, thermal stress cycling, and transient thermal shock.
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2025, Vol. 39 
