Cosmetic Welding of Copper Sheets and Cables
Cosmetic Resistance Welding of Copper sheets and cables: IWSL’s New Method Permits high quality welding of a variety of parts together
Common Issues With Joining Copper Parts Together
- Copper-copper sheet resistance spot welding is commonly not possible
- Bulk resistance of the copper parts welded and surface-to-surface resistance of the parts welded are too low for effective heat generation in common resistance spot welding (RSW)
- Copper stranded-wire cables of size above 15 mm2 in copper cross-section are not welded with adequate shear/peel strength by ultrasonic welding that is useful for smaller cable sizes
- Often expensive flux-cleaning followed by soldering or other expensive methods are used join bigger cables to connectors
- Hybrid/electric vehicles require such cable welds in large numbers
- Copper-copper sheet resistance spot welds are made possible by IWSL’s Focused-Melt Resistance Welding (FMRW) method
- Thick-Thin joints can be readily made
- Weld sizes are selectable
- Seam welds are possible
- Copper Cables are welded with high shear/peel strengths higher than soldered joints
- The joints are much less expensive to manufacture with high productivity and low labor costs
IWSL’s New FMRW Method Permits Inexpensive Resistance Welding of Copper Parts Together
IWSL’s New FMRW Method Permits Cosmetic Spot Welding of Copper-Copper Sheets
Peel Tested FMRW Copper-Copper spot weld demonstrates excellent fusion and weld quality
Copper and Aluminum Cables Resistance welded to Sheet and Box Connectors With A Variety of Coatings And Plating
High Shear Strength Weld Of A Connector Box With A 50 mm2 Stranded Copper Wire Cable With No Deformation Of The Box Connector
High Shear Strength Weld Of A Connector Box With A 15 mm2 Stranded Copper Wire Cable
How can the FMRW Welding Solutions help you?
Contact us to discuss your application, and how IWSL’s patented technology can increase your efficiency, quality and profitability.