What It Does 

Percussion Welder provides micro-welding solutions for many industries. It joins small metal parts, including dissimilar metals, intricate components and parts made in high volume, and it can be adapted to your application.

The weld is a capacitor-discharge arc between two parts brought to a pre-set gap. The surfaces melt, the parts are driven together and they bond within milliseconds, with minimal heat effect and no solder, filler or flux. How it works explains the four stages.

One of the biggest micro-weld challenges in battery design and manufacturing is the need to join dissimilar metals. This often results in design modifications and inefficient workarounds that affect design integrity and battery performance. Percussion Welder joins dissimilar metals without any filler materials.

Battery tabs and interconnects join copper, nickel and aluminum, by hand or in automation and semi-automation. Sensors and light bulbs are other automotive components welded this way. Ask us about your specific requirement. See automotive and battery welding.

In the medical industry, the precision and reliability of welding are paramount. Percussion Welder creates strong, clean welds for medical devices, and our technology is used for medical components that require precise connections.

Medical devices are often small and intricate, made of dissimilar materials and complex components that need low resistance and high reliability. The process produces a minimal heat-affected zone and needs no filler, flux or solder. Ask us about your specific requirement, and see medical device welding.

Joining components like resistors, diodes and sensors can be challenging because they need low resistance and high reliability, and they often include heat-sensitive parts. Percussion Welder is used in electronics design and manufacturing, providing clean welds for dissimilar materials.

The weld joint has low or non-detectable electrical resistance, and the heating lasts only milliseconds, so the effect on surrounding material is minimal. See electronics welding.

Manufacturers use sensors in everything from appliances and automotive to medical devices. Sensors pose specific challenges that Percussion Welder addresses by creating strong, reliable, low-resistance welds between dissimilar metals without consumable materials like solder or flux.

The same approach joins thermocouple wire. You set the gap, weld energy and timing, and the system forms a butt weld without filler, solder or crimping. The 858 welds thermocouple wire of Types K, J, T, E, N, R, S and B, as well as exotic thermocouple alloys. See thermocouple welding.

Percussion Welder supports aerospace and defense customers. These programs often carry specific requirements, so ask us about your specific requirement. Many of our customers are under non-disclosure agreements, so we do not publish customer names.

Other uses on our site include heater elements and lighting fixtures, where similar or dissimilar metals are joined as butt welds without filler. See aerospace, defense, heater elements and lighting.

Percussion Welder completes welds in milliseconds and can be used for manual welding or integrated into automated production, in automation and semi-automation.

For quality control, the optional Percussion Weld Monitor compares each weld against a learned signature waveform and shows a Pass or Fail result.

The welder gives precise control for intricate welds, made without filler material. Parameters are set on the 858, and weld parameters can be documented for your process. See our services for process development and training.

Bring us your biggest micro-welding challenge and we can show you how Percussion Welder can help with performance, design and efficiency. Free applications tests of your materials are available, and we can run live, in-person tests at our lab at 7100 N Broadway, Denver.

Call 303-536-7838 or email sales@percussionwelder.com. You can also see the differences from other joining methods and our design help.