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Resistance Weld 3mil, 6mil and 24mil Sheets to Themselves and 60mil Cylinder

System 1:
CD600DP, 600ws capacitive discharge resistance welder
PGHP, finger trigger single probe hand piece with large alligator clip and wheel electrode attachment
1awg weld cables

System 2:
CD1000DPM2, 1000ws capacitive discharge resistance welder
PGHP, finger trigger single probe hand piece with large alligator clip and wheel electrode attachment
1awg weld cables

The tapered electrode is configured with an 1/8” diameter tip. The Alligator ground clamp can be attached directly to the part, or a grounding plane can be used. We prefer the grounding plane when making the sheet to sheet lap welds since the plane provides a good backing and distributes the energy evenly. The clamp can stick to the cylinder at higher energy levels.

Once the electrode is positioned on the part, the button on the hand piece is pressed to trigger the welder. Operators will need to get a feel for how much pressure should be applied since too much pressure can minimize heat and cause weaker welds, but too little pressure can cause arcing and sticking of the electrode.

0.003” welds:
The 3mil sheets are welded to the cylinder and each-other using the CD600DP set with Pulse 1 off, Pulse 2 at 200ws and total energy at 200ws. Pulse 1 can act as a “cleaning” pulse to remove oils prior to the main discharge and can be set to approximately 10-15% of the main energy if desired.

0.006” welds:
The 6mil sheets are welded by the CD600DP at 300ws total energy.

0.024” Welds:
Because of the thickness of the sheets, the CD600DP did not have sufficient energy to create strong bonds on the 24mil sheets. The CD1000DP was chosen instead and was set to 1000ws to perform the welds successfully. Even at 1000ws, the welds between the 0.024” sheet and the 0.060” thick cylinder are somewhat weak in the peel direction. The sheet to sheet welds are strong, however.

Summary:
The CD600DP and PGHP are capable of performing welds on 0.003” and 0.006”. We recommend the CD1000DP to perform the welds on the 0.024” samples and will also work well with the 3mil and 6mil samples. I would have no hesitation recommending the respective systems for quickly and easily welding.

Let us know if you have any questions.
Phone: +1-801-658-0015
Toll Free Phone: 1-877-786-9353
Email: sales@SunstoneEngineering.com
Website: www. SunstoneEngineering.com