Insights
July 17, 2023 · 2 min read · Process
Picture this: You work for a company that manufactures medical devices, and you just received a for design and development. The new client wants a prototype, but it requires welding small, very complex parts – all of which are made of different metals. And, of course, the sensitive components can't be damaged, nor can the welding process affect the overall performance of the devices. Sound challenging enough? That’s where micro welding enters the picture. This specialized welding technique is ideal for small, delicate components from different metals. Micro welding machines use low current and voltage settings to produce precise, controlled welds. The end result is a strong, reliable, and a nearly invisible weld. They're ideal for high-quality applications including medical devices, electronics, and aerospace components, to name a few. Here are some of the most common types of micro - welding and some of their most common applications:
Chapter 01 / 05
Laser Welding
Used for medical devices, electronics, and automotive parts, laser welding uses a focused beam that heats and melts the materials that need to be welded. This laser beam produces high energy in a small area; hence, why it’s used for small and delicate components. Laser welding is non-contact, too, meaning there is no risk of damaging the components during the welding. Due to the slow nature of heating, laser welding can often produce larger than desired heat affected zones(HAZ).
Chapter 02 / 05
TIG Welding
Tungsten Inert Gas (TIG) welding uses a tungsten electrode to produce an electric arc which melts the materials that will be welded. It’s known for producing high-quality, precise welds with minimal distortion and is therefore ideal for welding stainless steel, aluminum, and other non-ferrous metals. It’s commonly used in aerospace and medical applications.
Want to see it on your parts?
Send samples and we'll run test welds before you commit.
Chapter 03 / 05
Resistance Welding
This combines heat and pressure to join materials, which are placed between two electrodes. The ensuing electric current that passes through them generates heat, which melts and fuses the materials. Best used for small and delicate components, resistance welding is commonly used in the electronics industry.
Chapter 04 / 05
Micro TIG Welding
This is a specialized form of TIG welding that uses a smaller tungsten electrode and a lower current setting to produce precise welds. It’s typically used for small and delicate components and is a favorite of the medical device industry.
Chapter 05 / 05
Percussion Welding
This specialized form of welding uses an electrical discharge and a rapid impact to weld the materials. The process is quick, efficient and produces reliable, high-quality welds with no filler metals or filler materials. Commonly used in the aerospace and automotive industries, percussion welding is ideal for dissimilar metals. How big is the order? Or what about the size and complexity of the components you’ll be working on? Are you using dissimilar materials? And what’s the desired precision and reliability? Micro welding equipment is necessary if you need precise and reliable welds on small and delicate components.
today to discuss your specific micro welding application and how percussion welding may be a fit.
Keep reading
Percussion Welding: Superior Metal Joining for Small and Large-Scale Applications
Percussion welding's unrivaled precision makes it the go-to choice for applications where accuracy is non-negotiable. Unlike traditional welding methods that often result in heat-affected zones and distortion,
Read →Dissimilar Thinking #5: Process Optimization & Production Scale-Up – From Prototype to High-Volume Manufacturing
You've proven percussion welding works in the lab. Now comes the hard part: making it work at production scale with Six Sigma consistency. Episode 5 of Dissimilar Thinking is your field guide to process optimization and
Read →Battery Tab Welding at Scale: How EV Manufacturers Solve Copper-Nickel Production Challenges
When a major EV manufacturer ramped production to meet growing demand, their battery suppliers hit a critical bottleneck: traditional resistance welding couldn't reliably join copper terminals to nickel tabs at the
Read →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.
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