Frequently Asked Questions
Many electrical connections are made using resistance heating. The types of welds that can be made include fusion welds, solid phase welds and brazed joints. A typical automotive example of the use of resistance welding would be the projection welding of lead frame assemblies used in electronic control unit (ECU's) and power modules.
Other applications include the joining of copper wires to pins during the manufacture of coils. The coils can subsequently be used in relays, motors or alternators.
Resistance welding has the benefit of not requiring expensive jigging as the parts are clamped together prior to the weld being made. Normally the copper wire would have its insulation stripped prior to welding, but TWI has developed joining techniques that make the joint without having to remove the insulation, further simplifying the welding process. There is a wide choice of power supplies that will enable close control, in conjunction with a suitable electrode pair, of the joining process. A wide range of materials can be joined using this technique. Typical joint diameters range from 10µm to 2mm.
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