Language
When Welding Different Copper Terminals at Both Ends of Copper Braided Wire with a Medium-Frequency Spot-Welder, How to Avoid Overburning at One End and Cold Joints at the Other?
Oct 14,2026
When the two ends of copper braided wire are welded to copper terminals of different specifications with a medium-frequency spot-welder, the thickness, cross-sectional area, and contact condition of the two terminals differ. If the same set of welding parameters is used, one end easily gets excessive heat and overburns, while the other end gets insufficient heat and produces cold joints, causing inconsistent welding quality at the two ends of the same product.
I Main Hazards of Overburning at One End and Cold Joints at the Other
1.At the overburned end, the braided copper wires are burned and embrittled, the terminal is ablated and blackened, and weld-spot strength decreases.
2.At the cold-joint end, the weld spot is not firmly bonded, easily detaches under force, has high contact resistance, and there is a risk of heating and arcing during use.
3.If the welding parameters do not match and only one end is improved, the defect at the other end will further worsen.
II Main Causes of Unbalanced Welding Quality at the Two Ends
1.Differences inherent in the workpiece incoming material
2.Inconsistent contact condition of the tooling electrode
3.Welding process and equipment factors
III Key Points for Improvement and Control
1.Do good workpiece pretreatment to narrow the working-condition gap between the two ends
2.Optimize the tooling electrode to balance contact and heat-dissipation conditions
3.Rationally debug the welding process
4.Strengthen quality control during mass production
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.
Related News
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