Copper strip overlap welding

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I want to weld copper strip (pure copper) by overlapping two ends together. The strip size variate between 2~6mm in width and 0.2~0.8mm in thickness (wider strip is thicker, narrow strip is thinner). The welding need firmly for electricity current and a little high temperature. Please suggest which welding method could be used and which equipment should be used. Wish to get the detsiled information.

-- Joe Jianping Zhang (jzhang@pulseeng.com), May 17, 2001

Answers

Due to the electrical and thermal conductivity being relatively high, pure copper is not normally commercially resistance welded. If you were to continue to evaluate your application, I would suggest using capacitance discharge or high-frequency type equipment. Put the energy into the weld zone rapidly.

-- Bob Balla (bobballa@tjsnow.com), May 23, 2001.

we have solved the problem of joining copper strips at ford by resistance brazing using silver braze preforms and a single phase weld gun with our patented weld controller that holds heat to plus or minus one percent. since the silver has a remelt temp. much higher than the melt temp. we have had no problems with high temp. electrical conductivity is excellent. if you have questions on this proceedure, please feel free to ask.

-- thomas n. mitchell (info@atekcorp.com), May 24, 2001.

In the two applications that I have done with welding copper in the past my experience indicates that the easiest way to do it is with mid-frequency (what Bob referred to as High Frequency). It's ability to deliver large amounts of current quickly is the key. FWIW all mid-frequency controls are not created equally as far as rise time some deliver current much quicker than others.

jeff

-- Jeffrey A. Bertoia (jbertoia@slalomservices.com), May 25, 2001.


For this application, Cap Discharge is most likely best suited RW method, as it derives the fastest rise time with the most energy. However, ultrasonic welding would be the preferred method for bonding copper strips, in most applications. Kurt Tolliver Unitek Miyachi Corp.

-- Kurt Tolliver (kurt@unitekequipment.com), May 26, 2001.

You would ideally require a Capacitor Discharge welder.This will deliver the current in a short time.This also restricts the current from heating the whole copper strip,thus the energy is restricted to the weld zone only.

Ultrasonic welding could also be a possibility but i am not so sure about its capability while welding thicker foil.

-- Subhash Patwardhan (artech1@vsnl.com), June 16, 2001.



I have welded copper strips 6 to 12mm in width and .5mm thickness to 1.2mm thickness on a ultrasonic metal welding machine.Execellent result obtained.

-- A.K.Ramanandan (saisonics@yahoo.com), December 02, 2002.

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