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In Energy-Storage Copper Flexible Connection Nickel-Sheet Welding on the Polymer Diffusion Welder, Does Excessive Welding Pressure Cause Copper-Foil Compression Deformation?
Oct 27,2026
The polymer diffusion welder relies on the coordination of pressure, temperature, and holding time to make the copper foil and nickel sheet form atomic diffusion bonding. If the welding pressure is on the high side, the copper foil easily suffers compression deformation, along with various adverse problems.
I Manifestations of Copper-Foil Compression Deformation
1.Multiple layers of copper foil are squeezed and compacted, and the overall thickness becomes thinner.
2.Under squeezing, the copper foil shows bulging at the edge, copper-wire overflow, and fold misalignment.
3.After pressing, the nickel sheet easily presses indentations on the copper foil surface, and the workpiece flatness becomes poor.
II Causes of Deformation Triggered by Excessive Pressure
1.The copper foil itself is relatively soft, and its plasticity further strengthens in a high-temperature environment, easily producing squeeze deformation under high pressure.
2.The nickel sheet hardness is higher than that of the copper foil. During pressing, pressure concentrates and transmits to the copper foil, preferentially causing copper-foil squeeze deformation.
3.Gaps exist between the multiple copper-foil layers. When pressure exceeds the limit, the gaps are completely crushed, and the copper foil continuously flows and thins.
III Concomitant Welding and Performance Defects
1.The bonding layer between the copper foil and nickel sheet is over-squeezed, the effective bonding area decreases, and local poor bonding appears.
2.The copper-foil toughness becomes poor and easily cracks when bent; the squeezed-out burrs also bring a short-circuit hazard.
3.The conductive path is squeezed and disturbed, resistance consistency becomes poor, and local heating easily occurs after energization.
4.The nickel sheet shifts under force and the edge collapses, producing stress cracks at the bonding edge.
IV Factors Aggravating Compression Deformation
1.Excessive heating speed softens the copper foil in advance. At this time applying high pressure makes the deformation more obvious.
2.The incoming copper flexible connection is loose and not pre-pressed and shaped; under the same pressure it collapses more easily.
3.The graphite mold surface is uneven with parallelism deviation.
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)
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Email: wushijie@jshaifei.com