Insights
June 25, 2024 · 2 min read · Medical / Automotive / Electronics
COPPER ALLOY TO COPPER MICROWELD
Welcome to our series on the uses and applications of Percussion Welder’s microwelding solutions. In this series, we invite you to pause and consider your current welding challenges, reflect on past microwelding problems, and think about the upcoming challenges you might face. We are here to transform those challenges into reliable solutions.
Get Expert Answers
With a free phone or Zoom consultation, we can determine if your microwelding challenge is a candidate for our solutions. Reach out to us at 303-536-7838. Each week, we share a real-world microwelding problem that we have addressed.
This Week’s Microwelding Challenge and Solution
In this week’s spotlight, we delve into a challenge from the field of Surgical Device Welding. A surgical robotics device manufacturer needed to join a small copper alloy electrical connector to a copper conductor on a highly sophisticated piece of medical equipment. The extreme thinness of the connector material posed a significant challenge; welding the copper conductor without burning a hole in the connector required precision and expertise.
Our Approach:
- Tailored Engineering: Our team meticulously engineered the entire process, from selecting the right materials to choosing the appropriate plating.
- Custom Tooling: We customized the tooling with precise jigs to securely hold the micro parts during welding.
- Precision Execution: Each step was executed with utmost precision, ensuring the integrity of the weld without compromising the thin connector material.
The result? A reliable and efficient solution that not only solved the immediate challenge but also became an integral part of the client’s design and manufacturing process for multiple products.
Why Choose Percussion Welder?
Our solutions are custom-engineered from concept to completion, ensuring that every unique challenge is met with a tailored approach. We take pride in transforming complex problems into seamless solutions that our clients can depend on for their sophisticated equipment.
Send Us Your Welding Challenge
If you have a copper-to-copper welding challenge or any other microwelding issue, don’t hesitate to reach out. We’re here to help you achieve precision and reliability in your manufacturing processes. Stay tuned for next week’s Percussion Welder Challenge: Copper to Stainless Microwelding.
Keep reading
Microwelding Copper to Stainless Steel with the Percussion Welder
A microwelding example: welding copper to stainless steel with the Percussion Welder, how it was approached and the advantages of percussion welding.
Read →Copper Magnet Wire to Brass Washer: A Microwelding Example
A microwelding example: joining copper magnet wire to a brass washer for aerospace and defense, and how the Percussion Welder was used.
Read →Kanthal-to-Kanthal Microwelding with the Percussion Welder
A Kanthal-to-Kanthal microwelding example with the Percussion Welder: the challenge, why the process was a good fit, and key benefits.
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