Copper Wire Spot Welding

The theory is simple i ve got a handf.

Copper wire spot welding. 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. All welds were performed on the 3 66 mm faces of c101 copper wire. It is a application of high current and specific clamping pressures and diameters. 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.

Spot welding copper requires special electrodes and brazing paste in order to achieve the same sturdy welding job that can be more easily achieved with metals such as steel. Predominately c101 copper wires were used but some weld trials were also performed with c110 copper wires. I believe some electric components are spot welded. 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.

It is often necessary to raise the temperature level of the sheet in an area of 6 0 to 12 0 in. 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. Spot welding is a resistance welding process. 152 4 to 304 8 mm away from the weld.

To most manufacturers spot welding is the most economical way to join two pieces of sheet metal. 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. There s hundreds of welding instructables around many of them quite good.

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. Wires were welded with two geometries referred to as crossed and parallel as described below. Copper like other metal parts are. For a very brief amount of time.

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.