I am faced with a production problem. My knowledge of welding is very limited. I will be production welding copper strap ends together for electrical connections. The strap is 3/16" x 5/16" diameter and the ends will be weld attached along the 3/16" edges with a 1/2" weld at their ends (side by side). What is the best (and reasonably economical) welding method to accomplish this with electrical welding? I have hand produced this connection with good results using phos copper and oxyacetylene, but it is not very conducive to production quantities.

-- Paul Frahm (prfrahm@msn.com), September 27, 2001

Answers

Paul, we worked with Ford on a similar problem and found that the only reliable method wes to use a silver braze preform and then resistance braze the joint. They spent a lot of money on other methods including ultrasonic welding. The resistance brazing weld schedule was set up to accomadate the required change between the first several brazes and the remaining run once the tooling has reached a steady temp. If you decide on this method, I will be happy to supply more info. Tom

-- tom mitchell (info@atekcorp.com), October 01, 2001.