Stranded wire is used in many industries including automotive and electrification, resulting in many types of wire fusing applications. One of the benefits of fusing is that the enamel can be removed during the fusing process rather than a separate stripping process....

Seam sealing is a technique used to seal electronic packages in a controlled environment, ensuring there is no oxygen or moisture in the package/electronics when it is sealed. The packages sealed in these environments are used in a variety of high-tech, high-value...

Stranded wire compacting is a resistance welding technique which is used to compact stranded wire into a single solid piece of copper. This makes the end of the wire easier to weld / connect to another component.

Catheter guide wire welding of SUS wire to a Ni alloy using resistance welding can result in the weld being brittle and of low structural integrity. One way of mitigating these 2 potential issues is to use closed loop feedback and the multi-step function in the...

The task for this application was to weld copper stranded wire to a brass ring. This was successfully done with the NRW-IN400PA High Frequency Inverter Welder. This welder utilised its closed loop feedback to monitor and adjust the current waveform during the weld....

Thermocompression bonding is a micro-joining technique where the components are heated and compressed, creating a solid-state joint, rather than a fusion weld. This type of application appears when 1 or more of the components may be adversely affected by too much heat...

Heat Staking CaulkingHeat Staking Caulking – Heat Staking or Caulking is a process used to join two plastic or metal components together without welding or gluing the parts together. The two components will come together with one component having the male part, which...

FPC to PCB Hot Bar SolderingHot Bar Soldering is a joining technique used for joining FPC’s to PCBs or Ribbons to PCBs, or wires to PCBs. Typically, both components to be joined will be pre-soldered, but just one is also possible. A pulse heat power supply and hot bar...

Hot Bar SolderingHot Bar Soldering is a joining technique used for joining FPC’s to PCBs or Ribbons to PCBs, or wires to PCBs.Typically, both components to be joined will be pre-soldered, but just one is also possible. A pulse heat power supply and hot bar bonding...

ACF BondingAnisotropic conductive film, commonly called ACF Tape is used in a bonding technique called ACF Bonding. ACF Bonding is used for joining FPC to PCB or FPC to LCD Panel. ACF Bonding is used where the pads on the PCB/FPC are extremely fine and the pitch...

Wire Compacting Wire Compacting is a very common resistance welding technique, which is commonly used in automotive applications where stranded wire needs to be joined to another component. Resistance welding stranded wire to other components offers many challenges,...

Stator & Commutator WeldingStator and Commutator Welding involves welding enamelled copper wire to a commutator, or enamelled copper wire to a busbar in a stator. Both applications require the enamel to be burned off prior to creating the weld. A high frequency...

Solar Panel Welding Solar Panels include many areas for micro-joining, including wires to junction boxes, diodes in junction boxes and copper tape to copper tape. These images show a diode to junction box application. For this application, a high frequency inverter is...

Hot CrimpingHot Crimping is a technique used to burn away the enamel on coil wire before welding it the wires together as well as with the crimp which is around the wire. A high frequency inverter at high current is typically used for this type of application, with...

Copper Battery Tab Welding As battery technology improves and the current capacity of battery packs increase, the bus bar material used in battery packs is required to be more conductive. Therefore, copper alloys are more and more commonly used for battery tabs and...

Battery WeldingUsing 18650 or 21700 cells in battery pack assembly is very common. When a module of cells is assembled, the individual cells need to be joined together by battery tabs/busbars. The Avio High Frequency Inverter is ideal for this type of application....

Battery Tab with Projections and Slits As battery technology improves and the current capacity of battery packs increase, the bus bar material used in battery packs is required to be more conductive. Therefore, copper alloys are more and more commonly used for battery...

Battery Pack WeldingUsing 18650 or 21700 cells in battery pack assembly is very common. When a module of cells is assembled, the individual cells need to be joined together by battery tabs/busbars. The Avio High Frequency Inverter is ideal for this type of...

ThermocompressionThermocompression is a technique used for very fine applications like fine wire, for example. This technique heats up the material and compresses it the other component forming a solid-state joint, rather than a fusion weld or a reflow joint. For very...

Tack WeldingTack Welding is the method of tacking components in position before they proceed on to the next manufacturing process, which is usually brazing. Tacking can either be done very precisely with the aid of jig and fixtures, or it can be done by hand. Tacking...

Sensor WeldingSensor Welding, including gas sensors welding and thermocouple welding typically involves weld very fine applications. For very fine applications like this, a linear DC welder is ideal because of the extremely fast switching time of the weld current....

Seam WeldingSeam Welding for wire mesh applications for filters, for example, the Sunstone Capacitive Discharge Welder with Roll Spot functionality is ideal. Using this function with the hand-held probe with seam welding wheel is a perfect solution for seam welding...

Resistance Welding ElectronicsFor carrying out fine welds on electronics, for example PCBs, high accuracy, low current welding is crucial. For very fine applications like this, a linear DC welder is ideal because of the extremely fast switching time of the weld...

Precision Resistance WeldingFor carrying out precision resistance welding, for example PCBs, high accuracy, low current welding is crucial. For very fine applications like this, a linear DC welder is ideal because of the extremely fast switching time of the weld...

Parallel Gap WeldingFor carrying out Parallel Gap Welding, for example, gold ribbon bonding, high accuracy, low current welding is crucial. Gold ribbon bolding is typically used in aerospace applications or laser applications.For very fine applications like this, a...

Honeycomb WeldingHoneycomb welding is typically used in aerospace applications or in turbine applications where a metal honeycomb structure brazed into an engine housing or a turbine housing, providing a tight seal between the engine/turbine housing and the rotor...

Filament WeldingFilament Welding typically involves welding very fine filament wires; a linear DC welder is ideal because of the extremely fast switching time of the weld current. There is also extremely low current ripple which is required for very fine applications...

Copper Tab Micro-TIG WeldingAs battery technology improves and the current capacity of battery packs increase, the bus bar material used in battery packs is required to be more conductive. Therefore, copper is more and more commonly used for battery tabs and bus bars....

Battery Tab Welding