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Troubleshooting Methods for Micropores & Bubbles Caused by Pressure Decay on Hydraulic Polymer Diffusion Welders
Aug 07,2026
Flexible power connectors are key parts guaranteeing stable current transmission in power transmission and new energy storage sectors. Welding quality directly determines power system safety. Hydraulic polymer diffusion welders deliver stable pressure via hydraulic systems to achieve tight interlayer bonding without welding filler.
I Correlation & Manifestations of Pressure Decay, Micropores and Bubbles
Stable pressure compresses interlayer gaps and expels air & moisture during welding; pressure decay will induce defects. Micropores are tiny holes visible to naked eyes on welding surfaces and edges; bubbles mostly hide inside the workpiece and cause loose interlayer bonding, often accompanied by surface blackening and slight separation between layers. Workpieces tend to fracture at defective positions under tension. The core of troubleshooting is to locate pressure decay sources.
II Step-by-step Troubleshooting Plan
1. Inspect Hydraulic System
1.Hydraulic oil: Replace or top up with qualified oil if turbid, black, impure or insufficient;
2.Hydraulic pump: Repair or replace if abnormal noise, vibration, unstable continuous pressure drop or oil leakage occurs during startup;
3.Hydraulic valve block: Clean or replace valves if leakage at joints or unresponsive adjustment & severe pressure fluctuation;
4.Hydraulic cylinder: Replace seals or repair cylinder body if rod jamming, retraction failure or cylinder leakage;
5.Pressure sensor & control system: Recalibrate or repair if large deviation between displayed and actual pressure, unstable data after restart.
2. Check Welding Process Parameters
1.Pressure setting: Adjust pressure according to connector layers & thickness to avoid mistaking low set value for pressure decay;
2.Press timing & holding duration: Apply pressure before preheating and ensure sufficient holding time to fully discharge air;
3.Temperature coordination: Excess welding temperature softens connectors and distributes pressure unevenly, moderate cooling is required.
3. Inspect Raw Materials & Tooling
1.Workpiece materials: Clean oily & oxidized surfaces, screen flat wrinkle-free copper foils;
2.Tooling fixtures: Repair deformed worn jigs, clear foreign bodies on fitting surfaces to ensure full clamping.
4. Environmental Inspection
Humid environment makes connectors absorb moisture and accelerates aging of hydraulic components; extreme high/low temperature degrades hydraulic oil performance and triggers pressure drop. Temperature & humidity control is required.
III Rectification Suggestions After Troubleshooting
1.Hydraulic system: Replace standard hydraulic oil, carry out periodic inspection; repair or replace faulty components, optimize control parameters;
2.Process parameters: Match pressure with connector specifications, pressurize prior to preheating and extend holding time while optimizing temperature curve;
3.Raw materials & fixtures: Clean workpiece surfaces, screen qualified blanks, repair or replace jigs and adjust clamping force;
4.Environment: Install dehumidification & cooling equipment to stabilize workshop temperature and humidity.
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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