Manipulation and welding of metal spheres above 10 μm using needle-like probe

A needle-like probe is the simplest tool to manipulate fine spheres. It catches fine spheres by adhesion forces without any holding device. Metallic spheres of 10-100 μm are difficult to manipulate with the needle-like probe, because the gravity rivals the adhesion forces in the dynamics of the spheres. Large and heavy spheres arranged on a substrate are easily disturbed because of the same reason. Here, a manipulator equipped with a direct power source, which applies voltage to the probe, is fabricated. Large and heavy spheres are adhered by the controllable electrostatic force. Besides the manipulation, the apparatus is designed to weld the spheres by using the probe as electrode for spot/arc welding. Experiments on the manipulation showed that the probe caught gold spheres of 40-80 μm by applying 20-50 V and released by putting them down after cutting the power off. Following to manipulation, welding experiments were carried out at various conditions. Two power sources, a high-voltage and low-current power source and a low-voltage and high-current power source, and two welding methods, arc welding and spot welding, are examined. The experiments showed that the gold spheres of 40-80 μm can be welded by the spot welding using the high-voltage and low-current power source, of which maximum power rating is 10 kV×1 mA. The probe is kept to touch the sphere and 4 kV or more is applied. Electric sparks are generated at the interface of the probe and the substrate, and the sphere is welded to the substrate. In both the manipulation and welding, the contact pressure must be very low. A tower of gold spheres is fabricated as an example of three-dimensional microstructures composed of fine spheres.