Скачать или смотреть Stacking Perfection: Welding Hundreds of Aluminum Foil Layers in One Bond

Building Conductivity Layer by Layer: Mastering Ultra-Multi-Layer Aluminum Foil Welding with Diffusion Bonding.

When your design calls for an electrode or conductor with massive surface area and minimal resistance—like in supercapacitors or specialized magnetics—joining dozens or hundreds of ultra-thin aluminum foils into a single, solid electrical terminal seems impossible. Traditional welding destroys the foils. This video reveals the solution: the HAIFEI Aluminium Diffusion Welding Machine, which uses solid-state bonding to create a perfect, low-resistance weld across the entire cross-section of a multi-foil stack.

In This Video, You Will Discover:

The Solid-State Principle for Delicate Materials: See how controlled heat and pressure cause atomic diffusion at every foil-to-foil interface without melting, preserving the integrity and properties of each fragile foil layer.

Achieving Uniform Bonding Throughout: The key challenge is ensuring bonding energy reaches the core of the stack. Witness how our process parameters and tooling design guarantee a homogeneous bond from the top layer to the bottom.

The Result: A Monolithic Terminal from a Foil Stack: The transformation is remarkable. What was a loose pile of foils becomes a solid, machinable block with a welded terminal, ready for high-current connections.

Critical for Performance: This process is essential for minimizing equivalent series resistance (ESR) in energy storage devices and reducing eddy current losses in magnetic components by providing a ideal, consolidated current path.

Precision Engineering for Advanced Electronics:
HAIFEI’s technology serves the frontier of electronics and energy storage. Our collaboration with leading innovators in these fields, backed by our 40,000+ project experience, drives the development of specialized solutions like this. We provide the custom process development and precise control necessary to turn advanced material concepts into reliable, manufacturable components.

Key Features & Technical Benefits:

Zero Melting, Zero Damage: The foil edges and surfaces remain unaffected, crucial for maintaining electrical and thermal properties.

Full-Cross-Section Bonding: Ensures 100% of the foil cross-section participates in current conduction.

Exceptional Conductivity: The bonded interface approaches the conductivity of bulk aluminum, minimizing interfacial losses.

Process Consistency & Repeatability: Automated control guarantees every stack is welded identically, a must for component reliability.

Clean & Flux-Free: No contaminants are introduced at the critical foil interfaces.

Ideal Applications & Industries:

Supercapacitor & Advanced Battery Manufacturing: Welding electrode tabs for ultra-high-power-density cells.

Power Electronics & Magnetics: Fabricating consolidated terminals for high-frequency inductors, transformers, and current shunts.

Aerospace & Defense Electronics: Manufacturing lightweight, high-reliability busbars and conductive structures.

Research & Development: Prototyping next-generation electronic and energy storage devices.

Pushing the Limits of Multi-Layer Component Design?
If you are an R&D Engineer, Product Designer, or Production Specialist working on cutting-edge devices where traditional joining methods fail, diffusion welding is your enabling technology.

📞 Contact HAIFEI for a Collaborative Process Development Discussion:
🌐 Visit Our Website: www.busbarwelder.com
📧 Email Us Directly: [email protected]
📱 WhatsApp/Call: +86 158 1641 7853

Share your foil specifications and stack design with our application engineers. We can conduct feasibility studies and provide prototype samples to prove the viability for your most advanced projects.

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