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In Copper Braided Wire Press-Squaring with a Medium-Frequency Spot-Welder, Why Do Edge Fine Wires Easily Fracture?

Oct 12,2026

Copper braided wire press-squaring with a medium-frequency spot-welder compacts the loose wire bundle into a regular cross-section, providing a flat contact surface for subsequent welding.

I Hazards of Edge Fine-Wire Fracture

1.Fractured copper wires no longer conduct current, reducing the effective conductive area and increasing the temperature rise during operation.

2.Broken wires stick up, affecting appearance and hindering subsequent welding and assembly.

3.Strength at the broken-wire position decreases, and cracks easily continue to propagate after bending.

II Main Causes of Edge Fine-Wire Fracture

1.Poor mold structure and tooling condition

2.Improper press-squaring process parameter setting

3.Quality problems of the incoming braided wire

4.Influence of welding heat input

5.Inadequate wire pretreatment

III Prevention and Control Solutions for Edge Fine-Wire Fracture

1.Optimize mold and tooling control

2.Adjust press-squaring forming parameters

3.Strengthen incoming-material inspection and control

4.Control welding heat input

5.Do good pre-welding pretreatment

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 spot‑welding machines for 17 years. The company has obtained 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 spot‑welding machines, please contact us: 400‑0510‑750.

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