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What Defects Are Caused by Improper Pressure Parameter Settings in Copper-Foil Flexible-Connection and Copper Lap Welding with a Medium-Frequency Spot-Welder?

Oct 21,2026

When welding copper-foil flexible connections and copper base material in lap with a medium-frequency spot-welder, pressure is a core process parameter. Excessive pressure, insufficient pressure, or unreasonable pressure-timing matching all produce various welding defects.

I Welding Defects Caused by Insufficient Pressure

1.The workpiece contact surfaces do not fit tightly, contact resistance is unstable, cold joints easily appear, weld-spot pull force is insufficient, and the weld spot heats severely after energization.

2.The workpiece easily shifts slightly during welding, and the weld-spot position becomes skewed.

II Welding Defects Caused by Excessive Pressure

1.Weld-spot indentations are overly deep, and the workpiece shape deforms.

2.The electrode bears heavy load for a long time, and wear speed accelerates.

III Defects Caused by Improper Pressure-Timing Settings

1.Insufficient pre-pressure time: the electrode energizes before pressing the workpiece tightly, easily causing arcing and spatter, and producing porosity.

2.Too-short hold time: the electrode is released immediately, and the weld spot easily produces cracks.

3.Incoordinated pressurization rhythm: energization and pressurization are not synchronized, the workpiece slides, and local fusion is poor.

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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