Insights
39 articles
- 2026-05-27 · 2 min · Materials
Niobium to Tungsten Welding with Percussion Welding
Join niobium to tungsten at 100V - the highest energy weld in our database (28.10 J). Both refractory metals welded in atmospheric conditions. Superconductor and aerospace propulsion applications.
Read → - 2026-05-27 · 2 min · Materials
Tantalum to Copper Welding with Percussion Welding
Weld tantalum to copper without vacuum chambers. Microsecond arc completes before Ta oxidation. 3 verified parameter sets from 0.007" to 0.030" wire. Implants and capacitor leads.
Read → - 2026-05-27 · 2 min · Materials
Copper to Platinum Welding with Percussion Welding
Join copper to platinum for pacemaker leads, RTDs, and catalytic probes. 4 verified parameter sets. 5.5:1 thermal conductivity asymmetry solved by percussion welding.
Read → - 2026-05-27 · 2 min · Materials
Nickel to Steel Welding with Percussion Welding
Weld nickel to steel without carbon migration that weakens the joint. Sub-3ms cycle preserves metallurgy on both sides. Parameters for 0.025" and 0.040" wire.
Read → - 2026-05-27 · 2 min · Materials
Stainless Steel to Copper Welding with Percussion Welding
Avoid copper-induced hot cracking when joining stainless steel to copper. 0.50ms weld cycle prevents grain boundary penetration. Verified parameters for 0.030" wire.
Read → - 2026-05-27 · 2 min · Materials
Copper to Tungsten Welding with Percussion Welding
Join copper to tungsten despite a 2,337C melting point difference and zero mutual solubility. 5 verified parameter sets. Lighting, EDM electrodes, and aerospace applications.
Read → - 2026-05-27 · 2 min · Materials
Aluminum to Steel Welding with Percussion Welding
Bridge the 850C melting point gap between aluminum and steel. Verified percussion weld parameters prevent Fe2Al5 intermetallic formation. Automotive lightweighting applications.
Read → - 2026-05-27 · 2 min · Materials
Nickel to Copper Welding with Percussion Welding
Join nickel to copper wire for battery tabs, thermocouples, and heater elements. 6 verified parameter sets covering both orientations. 0.018" to 0.040" wire diameter range.
Read → - 2026-05-27 · 2 min · Materials
Copper to Steel Welding with Percussion Welding
Weld copper to steel despite the 5:1 thermal conductivity gap and 425C melting point difference. Verified parameters for 0.030" and 0.040" wire. No filler material needed.
Read → - 2026-05-27 · 2 min · Materials
Copper to Aluminum Welding with Percussion Welding
Join copper to aluminum wire without brittle intermetallics. 3 verified parameter sets from 0.010" to 0.030". Under 3ms cycle prevents CuAl2 formation. EV battery and aerospace applications.
Read → - 2026-03-27 · 4 min · Thermocouple
Welding Thermocouple Wire
Step-by-step guide to welding thermocouple wire by percussion welding. Covers bead junction formation, wire preparation, fixture setup, and verified parameters for common thermocouple types.
Read → - 2026-03-27 · 4 min · Process
Still Running a Superior 528 or MTI 628?
Considering an upgrade from a Superior 528 or MTI 628 percussion welder? What carries over to the Model 858 and when an upgrade makes sense.
Read → - 2026-02-02 · 4 min · Process
Wire Joining Methods Compared: Percussion Welding and the Alternatives
Soldering, crimping, resistance welding, and percussion welding for wire joining — compared on strength, conductivity, speed, and dissimilar metal capability. Decision guide for engineers.
Read → - 2026-02-02 · 5 min · Battery
Battery Tab Welding: Percussion vs. Spot Welding
Percussion vs. resistance spot welding for battery tabs: HAZ, cycle time, dissimilar metal capability, and electrode wear compared. Which method for copper-nickel and aluminum tabs?
Read → - 2026-02-02 · 5 min · Materials
Polarity in Percussion Welding: When It Matters and How to Get It Right
How polarity affects percussion welds of dissimilar metals: where the heat goes, when polarity matters, and a process for selecting and testing it.
Read → - 2026-02-02 · 5 min · Medical
Percussion Welding for Medical Devices: Training and Validation
How percussion welding fits medical device manufacturing: no filler, minimal heat-affected zone, operator training, IQ/OQ/PQ process validation and weld monitoring.
Read → - 2026-01-30 · 5 min · Process
The 5 Most Common Mistakes New Percussion Welding Operators Make
Percussion welding has a short learning curve. That doesn't mean it's mistake-proof. Here are the five ways new operators most commonly turn good parts into expensive scrap—and how to avoid joining their ranks. The good
Read → - 2025-12-11 · 5 min · Process
Setting Up Your First Percussion Weld: A Step-by-Step Guide
You have an 858 Percussion Welder, a 726 Bench Fixture, two pieces of metal that need to become one piece of metal, and approximately zero idea where to start. This guide is for you. Percussion welding isn't
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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.
How fast is a percussion weld?
Milliseconds, start to finish.
A human blink takes about 400 ms. The arc itself heats the parts for only a few milliseconds, which is why the heat-affected zone stays minimal.
Which metals can it join?
Dissimilar combinations are the specialty — aluminum, brass, copper, steel, titanium and many more.
Our lab database holds 131 tested weld schedules across 33 materials and 68 material pairs. Don't see yours? Send samples and we will develop and verify a schedule. Free applications tests are available.
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.
Still have a question? Tell us your weld challenge and an engineer will reply.
Start here
Share what you're joining and what's going wrong. We'll tell you straight whether percussion welding is a fit.
Prefer to talk? Book a demo or call 303-536-7838