Skip the scrolling. Use this tool to instantly find if we can weld your material combination—and get starting parameters:

Material 1 (Base) Material 2 (Wire/Part)

*Parameters shown are starting points from lab data. Exact optimization may vary based on wire diameter, part geometry, and specific application requirements.

Before we dive into specific combinations, let's talk about why some material pairings are easier than others. Understanding the metallurgy helps you predict success and optimize parameters for your specific application.

The Three Key Compatibility Factors

1. Melting Point Differential

In traditional welding, large melting point differences are a nightmare.

How the Process Handles It:

The arc melts the surfaces of both parts, and the process is over within milliseconds, so there is little time for heat to spread.

Examples From Our Lab Weld Schedules:

• Tungsten to Copper
• Tungsten to Aluminum
• Platinum to Copper

2. Intermetallic Compound Formation

This is the boogeyman of dissimilar metal joining. When certain metals mix, they form intermetallic compounds—brittle crystalline structures that crack under stress. Aluminum-copper is the classic example: slow cooling creates CuAl₂ and other compounds that make joints fail spectacularly.

The Speed Solution:

Intermetallic formation requires time and diffusion. The percussion welding process is over within milliseconds, which leaves little time for intermetallic compounds to grow.

Problem Children (that we weld anyway):

• Aluminum to Copper — Would form CuAl₂ in slow processes
• Copper to Tungsten — No solubility, prone to delamination in traditional methods
• Nickel to Aluminum — Forms brittle Ni-Al intermetallics slowly

3. Thermal Expansion Mismatch

Different materials expand and contract at different rates when heated or cooled. Large mismatches create residual stresses that can cause joint failure—especially problematic in traditional welding where the entire part experiences thermal cycling.

The Minimal HAZ Advantage:

The minimal heat-affected zone helps limit the thermal cycle that dissimilar materials experience, which reduces thermal expansion mismatch problems.

Let's break down the most common material families and what makes them great (or challenging) for percussion welding:

The Copper Family

Materials: Pure copper, brass, bronze, phosphor bronze

Copper Properties:

• Excellent Thermal Conductivity: Disperses heat rapidly, making the minimal HAZ even more pronounced
• High Electrical Conductivity: Preserved through the joint—critical for electrical applications

Star Combinations:

Copper to Aluminum Battery terminals, EV charging Copper to Tungsten Electrical contacts, electrodes Copper to Nickel Thermocouples, sensors Copper to Moly High-temp electrical contacts

Pro Tip: Copper oxidizes quickly. Surface preparation is critical—even a thin oxide layer can interfere with weld quality. Clean surfaces immediately before welding.

The Nickel Family

Materials: Pure nickel, Inconel, Monel, Kovar, Chromel, Alumel

Nickel Properties:

• Corrosion Resistance: Withstands harsh environments (body fluids, chemicals)
• Temperature Stability: Maintains properties across wide temperature ranges

The Refractory Metals

Materials: Tungsten, molybdenum, tantalum, niobium

The Extreme Performance Category:

• High Melting Points: Tungsten and tantalum melt at very high temperatures
• Extreme Environments: Aerospace, vacuum tubes, particle accelerators

The Precious Metals

Materials: Platinum, gold, silver, rhodium, palladium

When Precision Meets Prestige:

• Corrosion Resistance: Precious metals resist corrosion
• Electrical Contact Excellence: Reliability in high-end electronics
• Biocompatibility: Gold and platinum for long-term medical implants

High-Value Applications:

Platinum to Copper High-precision thermocouples for lab equipment Silver to Steel Electrical contacts, relay components

Our compatibility matrix gives you starting parameters, but real-world applications often need optimization. Here's how to dial in good welds for your specific requirements:

The Six Parameters You Control

1. Wire Diameter

What it affects: Total energy required, weld strength, joint size

Optimization tip: Thicker wires need more energy. If welds look weak, try slightly smaller diameter wire before cranking up voltage. Conversely, if you're getting excessive spatter, wire might be too thin for your energy settings.

2. Velocity Setting

What it affects: Gap-closing speed, impact force

3. Time (milliseconds)

What it affects: Total heat input, HAZ size, weld penetration

Optimization tip: Longer times aren't always better. Excessive time increases HAZ without improving strength. Start with recommended time and only increase if you're seeing incomplete fusion.

4. Capacitor Bank Size

What it affects: Available energy, arc intensity, repeatability

Optimization tip: Larger capacitor banks store more energy. Use the bank listed in the weld schedule for your material pair and wire diameter.

5. Voltage

What it affects: Arc temperature, penetration depth, spatter

Optimization tip: This is your primary "heat knob." Higher voltage = hotter arc = deeper penetration. But too much causes spatter and excessive HAZ. Adjust in small increments while monitoring weld quality.

6. Pulse Duration (Short/Long)

What it affects: Energy delivery pattern

Optimization tip: When in doubt, start with the recommended pulse setting and adjust voltage first.

Quick Troubleshooting Guide

❌ Problem: Weak or No Bond

Try:

• Increase the voltage in small steps
• Check surface cleanliness (oxides block bonding)
• Verify gap distance

❌ Problem: Excessive Spatter/Splatter

Try:

• Decrease the voltage
• Reduce time setting
• Switch to "Short" pulse if using "Long"

❌ Problem: Inconsistent Welds

Try:

• Increase capacitor bank size for more energy reserve
• Check part alignment and repeatability

❌ Problem: HAZ Too Large

Try:

• Reduce time setting
• Consider switching to smaller wire diameter

Didn't find your exact material pairing in our database? That's actually exciting—it means we get to develop new parameters together.

Send us your materials, we'll run test welds, and provide you with parameters—no charge, no obligation.

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Episode #3: Inside the Arc

The physics of the process—what actually happens when materials fuse.

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Episode #4: Application Engineering

Application notes for specific industries.

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Episode 3: Inside the Arc →

About Percussion Welder

Led by Collin Eidsness, our team specializes in percussion welding systems for precision metal joining across medical, automotive, aerospace, and electronics industries. We design, manufacture, and support percussion welding equipment. Parameters in this guide come from our lab weld-schedule database.