Videos 

Percussion welding is a capacitor-discharge arc process. Two parts are brought to a pre-set gap, an arc melts the surfaces, the molten surfaces are driven together and the parts bond within milliseconds, with no filler, flux or solder. These videos explain it at the bench.

• The first video above is the company's own "How it works" video.
• A short video on how the Percussion Welder works. Free applications tests are available
• How the Percussion Welder works: a walkthrough at the bench

For the written version, see how it works.

The Model 858 Percussion Welder is the controller and power supply, and the Model 726 Bench Fixture holds the parts. These videos show how to operate the welder, how to set it up and what the controls and fixture do.

• The YouTube videos are titled "How to operate", "Setup" and "Walk through".
• Step by step: how to operate the Percussion Welder
• A walkthrough of the Percussion Welder power supply adjustments
• A walkthrough of the Percussion Welder bench fixture

Equipment details are on the 858 and 726 pages.

Copper to steel and wire to steel are among the weld tests we have filmed. These videos show copper and copper-based wire welded to stainless steel and to steel, in slow motion and at close range under the microscope.

• Slow motion: copper wire percussion welded to a piece of stainless steel
• 18 AWG copper wire percussion welded to a stainless steel tube
• The process of welding a stranded copper wire to a stainless tube, including a look at where the wire breaks in testing
• Extreme close-up of 14 AWG, 42-strand 27% nickel-clad copper wire being micro welded to 304 stainless steel

Percussion welding butt welds stranded wire to stranded or solid wire, and works on fine wire. These samples show stranded and solid copper wire joined in several combinations.

• Percussion welding a 22 AWG stranded tinned copper wire to a resistor with a .022" lead
• Slow motion: 22 AWG tinned copper wire percussion welded to .020" solid tinned copper wire
• Slow motion: 18 AWG stranded tinned copper wire percussion welded to 17 AWG copper clad steel
• 18 AWG stranded tinned copper wire percussion welded to 17 AWG copper clad steel, with a close-up of the weld

More on this joint type is on the wire joining page.

These videos show aluminum, titanium and Inconel wire welded with the Percussion Welder, which joins metals without filler.

• 20 AWG soft aluminum wire percussion welded to 22 AWG tinned copper
• Joining a stranded copper wire to an aluminum disk, with a microscope close-up of the finished weld. Sound on
• Slow motion: titanium wire butt weld
• Two strands of .034" Inconel joined together with the Percussion Welder

The weld schedules cover 33 materials, and the material compatibility checker shows how a pair is rated.

A pull test pulls the welded wire until something fails. In percussion welds the wire often breaks before the weld, and these videos show where it broke.

• Pull test of a copper wire percussion welded to a stainless steel device
• 18 AWG stranded tinned copper wire welded to 17 AWG copper clad steel wire, then pulled to failure. Breaks at 46 lbs
• 20 AWG brass wire percussion welded to a .015" steel strip, followed by a pull test. The wire broke above the weld at 32 lbs

The "20AWG to Brass" YouTube video above is the company's own title for that sample.

The Percussion Welder joins dissimilar metals. These videos show dissimilar materials welded at the bench, a screw welded to a washer and the welder used in automation and semi-automation.

• How the Percussion Welder helps you weld dissimilar materials, with a demonstration at the bench. Copper, nickel and aluminum are shown
• Three different materials, aluminum, nickel and copper, welded and arranged into a stick figure, with the Percussion Welder tagline "Change what's possible."
• The Percussion Welder can be used in automation and semi-automation. Collin at the bench
• Slow motion: percussion welding a screw to a washer, a common micro weld for automotive components

Read more on dissimilar metal welding.