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Dual Power Supply: Breakthrough Solution for Series 6 Aluminum Busbar Welding
Jul 30,2026
Series 6 aluminum alloy busbars are core load-bearing conductive components of energy storage cabinets and high & low voltage electrical equipment. Their dense oxide film and narrow melting range bring challenges to traditional single-power diffusion welding and thermal fusion welding, such as uneven heat input, poor temperature control, insufficient alloy fusion and high welding stress, which lead to loose interlayer bonding, partial virtual joints and busbar deformation. The Haifei dedicated dual-power diffusion welder for 6-series aluminum is developed matching alloy characteristics, featuring independent zoned temperature control with two power sources to realize uniform fusion of multi-layer laminated surfaces.
I Customer Background & Pain Points
The customer produces 6-series aluminum busbars, aluminum connectors and power expansion joints for energy storage, high and low voltage distribution equipment.
Existing Process Defects
1.6-series aluminum alloy features high hardness and stable alloy structure. Single-power heating delivers uneven temperature with low precision, causing incomplete local fusion, tiny gaps and oxide interlayers. Insufficient conductive area increases contact resistance and abnormal temperature rise under heavy current.
2.Uneven heat input from traditional processes concentrates welding stress, resulting in warping, twisting and flatness errors. Finishing workpieces afterwards raises scrap rates.
3.Single heat source cannot maintain consistent temperature across wide & thick busbars, creating inconsistent fusion between edges and centers.
4.Heavy manual reliance, welding quality depends on operator experience with low production speed.
II Customer Requirements
1.Dual-power independent zoned heating for uniform full-surface temperature, eliminate inconsistent fusion between edges and centers of wide/thick busbars, reduce virtual joints, gaps and oxide layers, and improve fusion compactness.
2.Match exclusive process parameters for 6-series alloy to control welding thermal stress and mitigate busbar warpage.
3.Optimize dual-power coordinated temperature control to guarantee stable temperature without parameter drift during long continuous operation.
4.Flexible production for various thickness & width busbars, support parameter storage and traceability.
III Custom R&D Solutions
1.Process Verification: Conduct batches of dual-power zoned diffusion welding tests for busbars of different sizes. Optimize power ratio, constant temperature, holding time and cooling rate based on aluminum alloy oxidation & heat transfer properties.
2.Equipment Selection: Dedicated dual-power diffusion welder for 6-series aluminum. Low-temperature low-pressure diffusion welding without filler metal enables atomic interpenetration under constant temperature to form stable metallurgical bonding, lowering contact resistance consistently.
3.Fixture Design: Custom full-profile pressing jigs with multi-point balanced compression to compact laminated surfaces layer by layer and eliminate micro gaps.
4.Core Advantages
Uniform fusion: Even heating & firm bonding across all areas
Controllable deformation: Stable stress relief & good forming
Flexible compatibility: Storable parameters, fast product changeover
IV Delivery, After-sales & Customer Feedback
Pre-acceptance and continuous running test showed stable pass rate. All original production troubles were eliminated after put into use. The customer recognized our responsive and professional after-sales service.
V Haifei’s Mission: Meet Customized Customer Demands
Haifei adheres to the philosophy of "Creating Value for Customers". We develop customized equipment according to your welding requirements, whether you need automatic, integrated or whole-line solutions. We uphold the aspiration of "Striving for the Rise of Chinese Industry" and corporate values of Gratitude, Progress, Altruism and Win-win Cooperation, contributing to intelligent equipment manufacturing in China.
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Wuxi HAIFEI Intelligent Equipment Co., Ltd.
Wuxi HAIFEI Welding Equipment Co., Ltd.
Add: 28 Shuiyun Road, Yuecheng, Jiangyin, Jiangsu Province, China. (Postal Code: 214404)
Mobile: +86 18915302352
Email: wushijie@jshaifei.com