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

  1. 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)
  2. 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

    IWSL’s New FMRW Method Permits Inexpensive Resistance Welding of Copper Parts Together

  3. 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
  4. 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 Cosmetic Spot Welding of Copper-Copper Sheets

Copper spot weld peel test demonstration

Peel Tested FMRW Copper-Copper spot weld demonstrates excellent fusion and weld quality

Copper and aluminum welded sheet and box connectors

Copper and Aluminum Cables Resistance welded to Sheet and Box Connectors With A Variety of Coatings And Plating

connector box weld shear strength

High Shear Strength Weld Of A Connector Box With A 50 mm2 Stranded Copper Wire Cable With No Deformation Of The Box Connector

cable to connector box weld

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.

Contact Us