Percussion welding is a game-changer for the welding industry, providing a solution to the challenges faced when welding dissimilar metals. This micro-welding process has made a significant impact in various industries, including automotive, medical, and aerospace engineering, where precision and durability are crucial in component manufacturing.
Applications of Percussion Welding
Percussion welding is designed to join similar and dissimilar materials by creating a solid bond using a short electrical discharge that creates a high-temperature arc. A slight rapid motion and low pressure is then applied to hold the metals together, resulting in a joint with minimal Heat Affected Zone (HAZ) and maximum durability. Despite its many advantages, percussion welding is a complex process that requires great accuracy.
Common applications of percussion welding include:
- Attaching metal tips to valve stems
- Manufacturing medical devices
- Welding fine wire to lamp filaments for lighting
- Welding terminals on electrical components that other welding processes can’t achieve
- Substituting flash and stud welding to join dissimilar metals
Benefits of Percussion Welding
- Short welding cycle, less than a second
- No filler material is used, producing clean welds
- Reduced melting and heating due to short arcs
- Can weld heat-treated and cold-worked materials without annealing
- The interface withstands vibration
- Clean,repeatable welding of dissimilar metals like copper and steel with high weld strength
- Joins metals with high melting points, like molybdenum and tungsten
- Minimal HAZ
Limitations of Percussion Welding
- Limited to butt joins only
- Limited to “spot” welding, no seam welding
- Workpieces must be clean and free of dirt and oil for RF to start percussive arc welding
- Requires higher welding voltages of between 50 and 150 VDC
Despite its limitations, percussion welding has proven to be a powerful tool in creating clean, strong, low resistance welds of similar and dissimilar materials. With the latest percussion welding systems, achieving clean, precise, and high-quality welds has never been easier.