Скачать или смотреть Solid to Flexible: One MFDC Weld for Robust Copper Connections

Defying Physics: High-Strength MFDC Spot Welding of Solid Copper to Flexible Braids.

Copper’s high conductivity makes it notoriously difficult for resistance spot welding. This HAIFEI demo breaks the convention, showcasing our advanced MFDC (Mid-Frequency Direct Current) Spot Welding System successfully creating strong, low-resistance nuggets between solid copper parts and flexible copper braids. Discover the technology that combines the speed of spot welding with the capability to join challenging pure copper materials.

In This Technical Demonstration, You Will Observe:

The “Impossible” Nugget Formation: Close-up footage reveals a genuine metallurgical fusion nugget being formed at the interface of rigid copper and braided strands, not just a surface bond or mechanical crimp.

Overcoming Material Challenges: See how the precise, high-current output of MFDC technology overcomes copper’s low resistivity and high thermal conductivity to generate focused heat exactly where needed.

Versatility in One Platform: The same machine welds dissimilar copper forms—from solid busbars, terminals, or sheets to multi-stranded flexible jumpers—simplifying your production line.

Process Precision: Witness the controlled forge force and current profile that ensure consistent weld penetration without excessive indentation or damaging the delicate braid strands.

The HAIFEI MFDC Advantage: Precision Engineered for Performance
Not all spot welders are equal. HAIFEI’s MFDC systems are optimized with:

Extremely High, Stable Current: Capable of delivering tens of thousands of amperes in a perfectly controlled DC waveform, essential for copper.

Advanced Adaptive Control: Real-time feedback can adjust parameters during the weld cycle to compensate for surface condition or fit-up variation.

Robust Electrode Design: Special electrode materials and cooling strategies to withstand the demanding conditions of welding high-conductivity metals.

Why This Matters for Your Production:
This capability translates to fast, clean, and reliable joints for high-current applications where both mechanical strength and electrical performance are critical. It offers an efficient alternative to soldering, brazing, or mechanical fastening for:

EV Battery Pack Busbars: Attaching flexible braid jumpers to solid copper busbars.

Power Distribution Units: Welding braided ground straps or shunt connections to copper terminals.

High-Current Electrical Panels: Creating durable connections between solid conductors and flexible cables.

Proven in Demanding Environments:
HAIFEI’s solutions are born from real-world challenges. Our expertise, proven through 40,000+ implementations and trusted by Fortune 500 innovators, ensures that what you see in this demo is scalable, reliable, and ready for your factory floor.

Ready to Evaluate MFDC Welding for Your Copper Applications?
📞 Contact HAIFEI for a Technical Consultation & Sample Weld:
🌐 Visit: www.busbarwelder.com
📧 Email: [email protected]
📱 WhatsApp/Call: +86 158 1641 7853

Send us your copper and braid samples. Our engineers will test them and provide you with weld samples, cross-section analysis, and a data-driven process recommendation.

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