Copper Wire Spot Welding

Predominately c101 copper wires were used but some weld trials were also performed with c110 copper wires.

Copper wire spot welding. There s hundreds of welding instructables around many of them quite good. The theory is simple i ve got a handf. For a very brief amount of time. While joining sheet metal is the most common use for the process resistance welding rw equipment actually can be used for a large variety of joining and heat treating projects some of which are not so well known.

I m writing this one here to share a technique i ve developed that works quite well even on copper tabs for which it was designed. Copper is a highly conductive metal often used as the metal of the conducting electrode ends of spot welders complicating the process of spot welding it. I believe some electric components are spot welded. 152 4 to 304 8 mm away from the weld.

Spot welding is a resistance welding process. A form of resistance welding spot welding is one of the oldest welding processes whereby two or more sheets of metal are welded together without the use of any filler material. Resistance spot welding is a thermo electric process where heat is generated at the interface of the parts to be welded by passing an electrical current through them for a precisely controlled time and under force. The process involves applying pressure and heat to the weld area using shaped alloy copper electrodes which convey an electrical current through the weld pieces.

It is a application of high current and specific clamping pressures and diameters. Spot weld anything even copper. It is often necessary to raise the temperature level of the sheet in an area of 6 0 to 12 0 in. Copper like other metal parts are.

All welds were performed on the 3 66 mm faces of c101 copper wire. In welding copper sheets the heat is conducted away from the welding zone so rapidly that it is difficult to bring the temperature up to the fusion point. Equipment two welding machines were used in this study. Wires were welded with two geometries referred to as crossed and parallel as described below.

Dcd320 dc and cd resistance welder high precision power supply mwh3000 3000g parallel micro weld head linear prototype not pictured.