Percussive arc welding is a high-speed welding process which can be used to produce either a fusion or forge (solid phase) weld. An arc is struck between a wire and component (a fuse body for example).
Other arc-based processes require an inert gas shroud or flux covering to avoid oxidation of the molten material, but the extremely short arc duration in percussive arc welding means such measures are not required. The basic set-up for percussive arc welding is shown in the illustration.
Primarily, percussive arc is used for attaching pins (around 2mm or less in diameter) to components such as resistors, capacitors, etc. It is also widely used as a stud welding process for attaching anchor points to assemblies; for example, threaded studs are welded to test-structures to allow the attachment of fatigue/fracture monitoring sensors.
FAQ: What materials are suitable for percussive arc welding, and how should they be prepared?