Innovative Weld Solutions limited (IWSL) developed and built tooling to validate Cross-wire Resistance Welding of 0.25 inch conductor diameter stranded-wire copper cables to one another at right angles. These samples were successfully welded during July 2014 in IWSL’s high current resistance weld laboratory in Dayton, Ohio. A photo of one of these welds is shown below. Weld process windows were wide with more than a 12% current range in which good welds were made.
