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What Causes Local Non-Fusion in Lap Welding with Copper Diffusion Welder?
Sep 23,2026
In copper diffusion welder lap joints, partial non-fusion may appear: edges or certain zones fuse well, but some interior areas remain unconnected. The gaps or intermittent fusion can only be found after sectioning. The defect position is not fixed and appears intermittently.
I Hazards of Local Non-Fusion in Mass Production
1.Reduced effective connection area of the joint.
2.Locally missing conductive cross-section; contact resistance increases after energization, easily causing local overheating and excessive temperature rise.
3.Non-fused zones become stress concentration points and easily propagate into cracks under vibration and impact conditions.
4.Defects mostly hide inside and are hard to detect by visual inspection, so an entire batch may be missed in inspection and flow into downstream processes.
5.Poor process stability; with identical parameters, results fluctuate between good and bad.
II Core Causes of Local Non-Fusion
1.Poor interface condition and fitting.
2.Insufficient pressure or uneven pressure distribution.
3.Inadequate heat penetration and temperature gradient across the workpiece.
4.Improper holding time and cooling regime.
5.Drift of equipment and tooling condition.
III Improvement Solutions
1.Strictly control interface quality.
2.Ensure uniform pressure.
3.Optimize heat input.
4.Standardize cooling regime.
5.Maintain equipment periodically.
6.Manage parameters separately by specification.
Wuxi Haifei Intelligent Equipment Co., Ltd. https://www.haifeiwelder.com/
Wuxi Haifei Intelligent Equipment Co., Ltd. has been focusing on the R&D and production of diffusion‑welding equipment for 17 years. The company has passed ISO9001 Quality Management System Certification, China Compulsory Certification (3C) and CE Certification. It is a National High‑tech Enterprise, a Specialized, Refined, Differential and Innovative Enterprise of Jiangsu Province, a Specialized, Refined, Differential and Innovative Enterprise of Wuxi, and a Gazelle Enterprise in the Southern Jiangsu National Self‑Dependent Innovation Demonstration Zone.
Should you be interested in our diffusion‑welding equipment, please contact us: 400‑0510‑750.
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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