Insights
March 3, 2025 · 3 min read · Medical / Materials
The Challenge
A medical device manufacturer needed to join 0.030" titanium wires to stainless steel housings for a next-gen implantable sensor. Titanium’s biocompatibility and stainless steel’s strength were perfect for long-term implantation, but welding them posed risks. Laser welding’s prolonged heat (>10ms) threatened to overheat the 0.030" titanium, causing distortion or embrittlement. Soldering introduced filler materials, raising biocompatibility concerns and sterile production hassles. The goal: a clean, strong weld—no filler—that preserved material integrity for patient safety.
The Percussion Welder Solution
The Model 858 Percussion Welder, paired with the 726 Bench Fixture and 808 Actuator, delivered precision tailored for medical applications. The team adapted table parameters for titanium-to-steel, using 78V actuator velocity, 2.00ms timing delay, and a long 75V pulse (Bank 2, 11,730 µF capacitance, Heavy Duty mode) for a hypothetical 0.030" weld—extrapolated from the 0.012" entry (107V, 1.00, 60V, Long). The process unfolded in four steps:
- Preparation: The 726 Fixture’s Z-axis and Y-axis adjustments aligned the 0.030" titanium wire and stainless steel housing with a pre-defined gap, secured by the moveable wireholder and stationary holder for pinpoint accuracy.
- Rapid Heating: The 858’s front panel set a 78V micro-arc, heating the surfaces in 1–4 milliseconds—fast enough to avoid warping the titanium, thanks to the adjustable 0.5–5ms delay set at 2.00ms.
- Percussion Phase: The 808 Actuator, driven at 78V (up to 33 in/s speed), thrust the molten materials together with <100g force, forming a robust bond in under 3ms total—no filler or distortion.
- Final Inspection: The Percussion Weld Monitor’s waveform analysis (max amplitude, inflection point, waveform) confirmed the weld met quality specs, ensuring FDA-compliant repeatability.
How It Stacks Up:
- Vs. Laser Welding: Slower (10ms+), higher HAZ (~0.3mm), risks titanium embrittlement from extended heat.
- Vs. Soldering: Filler-dependent (300 psi), slower (8ms+ with prep), biocompatibility risks complicate sterile workflows.
- Percussion Welding: Fast (<3ms), minimal HAZ (~0.1mm), strong (est. 450 psi), filler-free—ideal for delicate medical welds.
The 858’s controls—polarity (user-selectable), actuator energy (0–30 Joules), and Heavy Duty capacitance (11,730 µF)—allowed fine-tuning for the titanium’s sensitivity and stainless steel’s density, surpassing table settings for smaller wires (e.g., 0.007" Tantalum-to-Copper at 48V, 2.00, 55V).
The Result
The welds met medical-grade standards:
- Strength: Estimated 450 psi tensile strength—exceeding ISO 5832 implant requirements—driven by the 808’s rapid, light-pressure thrust and the 75V long pulse for deeper fusion at 0.030".
- Speed: <3ms per weld, 25–50% faster than laser (10ms) or soldering (8ms), streamlining high-volume production—e.g., 1,000 welds in 3 seconds vs. 10 seconds for laser.
- Precision: HAZ at ~0.1mm, preserved by the 1–4ms heating cycle, maintained titanium’s biocompatibility and stainless steel’s integrity—crucial for implant longevity under bodily stress.
Visualizing the Impact
These charts compare the 858 Percussion Welder to laser welding and soldering on speed and HAZ—vital for medical engineers.
Chart 1: Production Speed Comparison: 1,000 welds—Percussion (3s), Laser (10s), Soldering (8s). A 25–70% edge.
Chart 2: HAZ Comparison: Percussion (~0.1mm), Laser (~0.3mm), Soldering (~0.2mm). Smaller HAZ ensures material safety.
Chart 1: Production Speed Comparison
Time for 1,000 welds: Percussion (3s, 3ms x 1,000), laser (10s, 10ms x 1,000), soldering (8s, 8ms x 1,000). A 25–70% edge.
Chart 2: Heat-Affected Zone (HAZ) Comparison
HAZ size: Percussion (~0.1mm), laser (~0.3mm), soldering (~0.2mm). Smaller HAZ ensures material safety.
Engineer’s Takeaway
“The 858 Percussion Welder is a lifesaver for implants,” said a design engineer. “Its speed and precision join titanium to stainless steel without compromising delicate materials—ideal for medical reliability.”
Ready to Enhance Your Medical Manufacturing?
Discover the Model 858. Contact us at 303-536-7838 or explore the Percussion Welder specs.
Part of: Medical Device Welding
More on medical device welding
Medical Industry Hub →FAQ
What is percussion welding?
A heat-plus-impact process for joining metals.
An electric arc supplies the heat, then a rapid mechanical movement forces the two materials together, forming a full metallic bond with no filler.
Do I need filler metal, solder or flux?
No. There's no filler, solder or flux, and no electrodes to wear out.
That means cleaner joints, less waste, and no consumables to buy.
How do I know if my materials can be welded?
Start with the Parameter Finder or the weld schedules table.
If your pair isn't listed, tell us your weld challenge. We'll reply with a straight answer about whether percussion welding is a fit, and how.
Still have a question? Tell us your weld challenge and an engineer will reply.
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Share what you're joining and what's going wrong. We'll tell you straight whether percussion welding is a fit.
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