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Percussion Welder

Insights

October 3, 2024 · 2 min read · Thermocouple / Materials

Chapter 01 / 02

Microwelding Challenges We Work On

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! We’ll tell you whether your challenge is a good fit for the Percussion Welder. The consultation is completely free. Reach out to us:

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 a Good Fit

The client reached out for a free consultation, and we determined that the Percussion Welder would be a good 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.

Key Benefits of the Percussion Welder Solution

Benefits of the Percussion Welder approach for this application:

  • 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 filler, solder or flux, and little or no clean-up.
↓Next: Submit Your Microwelding Challenge

Chapter 02 / 02

Submit Your Microwelding Challenge

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.

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

Part of: Process & Technique

More on process & technique

How Percussion Welding Works →

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

Tell us your weld challenge →