Heater Elements

Micro Welding Heater Elements

Percussion Welder is the ideal solution for aerospace micro welding. Our system is designed to provide exceptional welding between similar or dissimilar metals,providing weld joints with near-zero electrical resistance.

Aerospace welding using percussion welding offers a superior butt weld that can stand up to the demands of the application. In aerospace welding, adherence to specific welding requirements is mission critical, and our percussion welding system offers the solid weld interfaces required.

The Percussion Welder Solution to Heater Elements Welding

To address this issue, Percussion Welder has created a micro welding solution that is designed to quickly, precisely, and accurately micro weld with popular types of metals such as copper, kanthal, and stainless steel, to name a few. Our system allows you to weld similar or dissimilar materials using a controlled welding process that produces superior-quality butt welds.

The welds are strong, and due to the percussion welding process, they do not require cleanup after the weld, as found with some traditional heater element welding techniques. The controlled gap, electrical arc, and percussion during the process combine the molten material to the bond, producing a complete weld around the piece in its exact positioning without using any filler metal or material. Due to its brief heating duration, typically under 3 milliseconds, the impact of heat affected zone (HAZ) is kept to a minimum, resulting in negligible or no detrimental impact on the materials.

Percussion Welder technology results in a near-zero resistance joint that can be used on any heater metals. The welds are uniform and with our Percussion Welder Monitor, each weld can be verified as good/no good as part of overall quality control standards.

858 Front Panel
858 Front Panel

High-quality heating elements are essential for many manufacturing processes, and the challenge of attaching them securely can be complex. Fortunately, Percussion Welder offers an efficient solution to this task. With our unique technology, micro welders can heat and connect even the most delicate of wires quickly and easily. Due to its brief heating duration, typically under 3 milliseconds, the impact zone of heat (HAZ) is kept to a minimum, resulting in negligible or no detrimental impact on the materials.

The Benefits of Percussion Welder for Welding Heater Elements

Using Percussion Welder for heater elements assembly welding results in welds that are streamlined and are no larger than the diameter of the lead. Our team works closely with each client to create a custom solution for micro welding heater elements that fully integrate with your production, automation, or manual welding requirements.

Percussion Welder has taken micro welding one step further by providing expert consulting services to its customers. If you’re looking to bring precision energy control and reliability into your product, our experts are available. Contact us today if you are interested in upgrading your current heater element welding equipment to our Percussion Welder system. We are also available to answer your questions through our online contact form. With the help of our innovative micro welders, rest assured knowing you’ve secured reliable, precise energy control while keeping up with industry standards.

Adjustments & Features of the
Model 858 Front Panel

858 Front Panel

Actuator: The actuator setting
controls the charging voltage of the
capacitors that energize the
electromagnetic actuators. The range is
0 to 150 volts. The actuators move
the weldments together
during the welding process.

Delay: The delay is 0.5 to 5.0
milliseconds between actuator
initiation and discharge
of weld energy.

Weld: The weld energy voltage
control determines the charging
voltage applied to the
weld capacitors. The range
is 0 to 150 volts.

Mode: There are two mode settings,
regular and heavy-duty.
Heavy Duty adds an additional
bank of capacitors to
the weld output.

Pulse: The long / short pulse
width switch provides the
operator with pulse
width control. A long pulse
delivers less peak energy
for a long time
than a short pulse.

Polarity: Controls the direction of
weld energy electron flow.
The direction of electron flow
affects the amount of
heat applied to each weldment.

Capacitance: This setting controls the
amount of capacitance in the
weld output circuit. There
are three capacitance
ranges labeled 1, 2 and 3.

Operation so simple and intuitive on model 858, we can show you how to use it in less than 60 seconds

If you’re like us, sometimes a picture (or video) is worth a thousand words. Watch our 60-second video showing you step-by-step how easy Percussion Welder 726 Bench fixture is to operate.

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For more demos, slow-mo’s, and closeups of the action.

Let's Talk

No matter what your micro-welding challenge is, the Percussion Welder team at MTI Microwelding is available to offer guidance, answer questions, and even run live, in-person tests using our equipment.

See Potential? Let's Discuss Your Application

After exploring the advantages of percussion welding for small components, are you eager to see how it could benefit your specific application? Schedule a 15-minute consultation with our experts to discuss your project and explore the possibilities!