Copper Magnet Wire to Brass Washer: A Microwelding Example 

At Percussion Welder, we’re passionate about tackling the seemingly impossible. From medical devices to robotics and aerospace, if your small component microwelding project has left you at a standstill, we may be able to help. Each week, we showcase a real-life challenge submitted by one of our customers, highlighting how our microwelding technology overcomes even the most complex problems.

Have your own challenge? Contact us for a free consultation by phone, email, or Zoom, and we’ll tell you whether your microwelding problem can be solved using the Percussion Welder.

This Week’s Challenge: Copper Magnet Wire to Brass Washer in Aerospace & Defense

This week’s challenge comes from one of our Aerospace and Defense clients. They reached out to us with a critical problem that, if unresolved, could have stalled their project: How do you weld an extremely thin copper magnet wire to a delicate flat brass washer?

Let’s break it down:

• The materials: A 0.25-millimeter copper magnet wire needed to be welded to the inside diameter (ID) of a brass washer that was less than ¼ of an inch thick.
• The issues: The copper wire lacked columnar strength, making traditional welding methods like resistance or laser welding ineffective. On top of that, the weld had to be performed at a 90-degree perpendicular angle—a difficult feat on such tiny components.

After attempting other methods with limited success, the client turned to the Percussion Welder to solve this problem.

Our Approach: Welding with the Percussion Welder

The beauty of the Percussion Welder is its ability to handle even the most delicate welding situations. Unlike resistance welding, which requires pressure, or laser welding, which is difficult to direct in tight spaces, the Percussion Welder performs precise microwelds with minimal pressure.

Here’s how we tackled this challenge:

• Minimal Pressure: Since the copper wire had no columnar strength, the welding method needed to exert almost no pressure—an ideal scenario for our technology. The materials only needed to lightly touch to create the weld.
• Dissimilar Metal Welding: Welding copper to brass can be tricky, but the Percussion Welder can join these two metals despite the difference in material properties.
• Precision at an Angle: The client needed the weld to be made at a 90-degree angle to the inside edge of the brass washer. The precision of the Percussion Welder allowed us to weld at this challenging angle without compromising the integrity of the joint.

Testing the Solution

Once we identified that this project was a great candidate for our solution, we had the client send us their materials. After conducting test welds, we confirmed that the welds were successful. The next step was to send the welded materials back to the client for their own testing.

The result? Our Aerospace and Defense client reported that the welds met their requirements.

Have a Microwelding Challenge?

Are you working with microscopic components or facing welding issues due to the size, strength, or materials involved? Whether your problem involves dissimilar metals, hard-to-reach angles, or delicate materials, the Percussion Welder can provide the solution you need.

We offer a free consultation by phone, email, or Zoom to discuss your specific microwelding challenge. We’ll tell you if the Percussion Welder is right for you, no strings attached.

• Call: 303-536-7838 (Denver, Colorado, U.S. Mountain Time Zone)
• Email: sales@percussionwelder.com
• Schedule a Zoom Call: Click here to schedule

We look forward to solving your microwelding challenges—no matter how complex they may seem!

At Percussion Welder, we don’t just solve problems; we create long-lasting solutions for even the most difficult microwelding challenges. Let us help you take your project to the next level.