Related Product: sunstonewelder...
Related Product: sunstonewelder...
System 1:
CD200DP-RS, 200ws CD resistance welder with roll spot mode programming
PASP HP, pressure-actuated single probe handpiece (high power) with wheel electrode attachment
Copper grounding plane
1awg weld cables
The welds were performed using the CD200DP-RS coupled with a pressure-actuated handpiece and a wheel electrode attachment. We used a copper grounding plane for the welds but a grounding clip could be attached to the metal directly for similar results.
Consistent operator hand speed plays a large role in the consistency of distances between spots. The slower the rate of travel, the closer together the spots. Too long of a dwell in one place, however, can lead to sticking and blowouts. The CD200DP-RS was set to actuate welds at intervals of 0.1s for all the samples (resulting in the smallest interval possible according to energy level). The handpiece is set to deliver maximum spring force.
Welds were performed for each configuration at the following settings:
0.0015” soft Al lap welds - Pulse 2 at 10ws, Total Energy at 10ws
0.0015” hard Al lap welds - Pulse 2 at 15ws, Total Energy at 15ws
0.004” soft Al lap welds- Pulse 2 at 50ws, Total Energy at 50ws
0.004” hard Al lap welds - Pulse 2 at 50ws, Total Energy at 50ws
Once the top side is welded, the sheets are flipped over and another line is welded along the seam for increased strength and to eliminate the “flap” of the overlap.
We were able to overlap the foil at approximately two millimeters but a fixture to hold the sheets in their proper orientation would be ideal. The resulting welds are strong, but as you experiment further with your product you will be able to dial in the settings even more to achieve desired results.
Summary:
The system outlined above can quickly and easily perform these weds welds. The roll spot method is a quick way to perform a line of several weld spots without having to raise and lower an electrode for each attachment point. A sliding weld head holding the wheel electrode could help automate the process and increase productivity. I would have no hesitation recommending the CD200DP-RS for your application.
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Website: SunstoneWelder...