Solve Unsolvable Microwelding Problems: Kanthal-to-Kanthal Welding with Percussion Welder 

At Percussion Welder, we specialize in solving the unsolvable. Whether you're in medical device manufacturing, robotics, electronics, or automotive industries, if you have microwelding challenges, we’re here to help.

Thank you to everyone who continues to submit their unique microwelding challenges. We love turning your tough problems into long-lasting, reliable solutions!

Got a microwelding issue you’ve been struggling with? Let us know! In just five minutes, we’ll tell you whether your challenge is a good fit for the Percussion Welder. The consultation is completely free. Reach out to us:

• 📞 Call us at 303-536-7838
• 📧 Email: salesd@percussionwelder.com
• 📅 Or schedule a Zoom consultation

This Week’s Challenge: Kanthal-to-Kanthal Welding

This week, a client who manufactures heater elements and cartridges for industrial processing equipment came to us with a serious problem: they needed a reliable method to weld Kanthal wires. Their existing process involved crimping and TIG welding, but it was riddled with issues:

• Unacceptable failure rate: Joints were breaking far too often.
• High resistance at the joint: This created operational inefficiencies.
• Labor-intensive process: Crimping and TIG welding were consuming time, labor, and resources.

Why Percussion Welder Was the Perfect Solution

The client reached out for a free consultation, and in just five minutes, we determined that the Percussion Welder would be a perfect fit for their Kanthal-to-Kanthal welding needs. After receiving their materials, we performed a series of test welds on various diameters of Kanthal wire and sent the results back for their own testing and evaluation.

Proven Results: Stronger Welds, Less Downtime

Not only did the welds pass the client’s initial tests, but they also held up under intense temperature cycling and vibration testing. To ensure thorough validation, the client sent the welds to an independent testing lab at a major university, where they passed stress tests with flying colors.

If you’re a numbers person, here are the impressive test results:

• The client’s original TIG weld on larger-diameter Kanthal wire broke at 346 newtons. The Percussion Welder microweld? It held strong up to 933 newtons – nearly three times stronger!
• For smaller-diameter wire, the customer’s process resulted in breaks at 280 newtons. Our welds didn’t break until 685 newtons, making them about 2.5 times stronger.

Key Benefits of the Percussion Welder Solution

After seeing the performance improvements firsthand, the client transitioned their entire manufacturing process to use the Percussion Welder. The benefits extended beyond stronger joints:

• Simplified Process: The old method required crimping, sleeving, and TIG welding. With the Percussion Welder, it’s as simple as aligning the wires and making the weld – no extra steps, no clean-up, and no additional materials.
• Improved Efficiency: The streamlined welding process significantly reduced labor and production time, cutting down costs.
• Reliability in the Field: The client no longer deals with field failures or high resistance across the weld joint.

We invite you to submit your own microwelding challenges. Whether it's a past issue or a problem you’re currently facing, we’ll tell you if the Percussion Welder is the right solution for you. Five minutes is all it takes to find out.

• 📞 Call: 303-536-7838
• 📧 Email: salesd@percussionwelder.com
• 📅 Zoom: Schedule a consultation

Bonus Insight: Comparing Our Process to Competitors' Patents

For those who love the nitty-gritty, here’s an interesting fact. We recently came across a patent application for a Kanthal welding process filed by a Chinese company. Their approach? Complicated, convoluted, and inefficient. Our process? Simple, clean, reliable, tested, and incredibly cost-effective. Sometimes, less really is more.

At Percussion Welder, we solve the unsolvable. Let us help you with your toughest microwelding problems. Reach out today!