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  1. Q

    kWeld - "Next level" DIY battery spot welder

    Better just crimp, or solder. Or if you crimp before soldering, than first apply some flux and crimp very lightly. Although soldering large cables may seem complicated, it is not. With proper tools it can even be easier than crimping. Simplest way is a large soldering iron, but you can damage...
  2. Q

    kWeld - "Next level" DIY battery spot welder

    But it's not that simple. In galvanic corrosion the anode gets all or most of the corrosion. - anode - washers - zinc plated mild steel - cathode - fuse - gold plated brass or copper (alloy) But here the cathode gets significant damage too, probably even more than the anode. Not advisable...
  3. Q

    kWeld - "Next level" DIY battery spot welder

    These are great, and I think I looked at them. But the problem is 300 A and 400 A are only 11 mm for M10. I forgot to mention, that ANL fuses can be 9 mm for M8 and 11 mm for M10. They have holders, and there are other holders, but the cable shoes are the problem. In 9 mm they have 325, 355...
  4. Q

    kWeld - "Next level" DIY battery spot welder

    On the other side. Here it just senses the voltage and gets power for the electronics. It's a small PCB trace, that I think goes trough a resistor, and is connected to that side of the fuse that gets power from the super capacitors. Here a small jumper wire will be needed. Part of the problem...
  5. Q

    kWeld - "Next level" DIY battery spot welder

    For small size resistors there must be no difference. I can confirm this using LCR meter that goes from DC up to 100 kHz. Than it's definitely not the resistor. Quality resistors with a wrong marking is highly unlikely. So it may definitely need recalibration, if possible, or it has a fault...
  6. Q

    kWeld - "Next level" DIY battery spot welder

    Yes, I got the ones linked, and also others of the same size. But it's not from a reseller or the manufacturer. A company closed operations and sold various spare parts related to welding - both regular welding and spot welding. I got them quite cheap (new old stock), for something around 30...
  7. Q

    kWeld - "Next level" DIY battery spot welder

    With these you may be able to weld coper only directly. But I don't know whether you need copper only at all. The sandwich method is more complicated, but it's structurally stronger. Using only 0.1 mm copper may me too weak in some cases. Do you have a link or at least where they were sold? I...
  8. Q

    kWeld - "Next level" DIY battery spot welder

    I just already have them. They are a surplus from a project, and probably I will not have any other use for them. You mean, that the charger is at a fixed voltage, and to go down a separate discharger is used? Several years ago I thought about that and got several DC contactors. But never had...
  9. Q

    kWeld - "Next level" DIY battery spot welder

    There are two reasons for that larger force. One is that the Nickel plated steel is harder than pure Nickel. And the other is that your hands do not act like a spring, applying the same force when the parts to be welded heat up and compress. If the forces are too low, than there will be sparks...
  10. Q

    kWeld - "Next level" DIY battery spot welder

    I use the original electrodes and the force allied is somewhat higher - 6 to 10 kg. Got the same head as yours from aliexpress, but it's still not in use. Hope to test it soon and compare with you results. Industrial pneumatic heads go from around 200 g to 10 kg per electrode. This means from...
  11. Q

    kWeld - "Next level" DIY battery spot welder

    Thanks. But will the enclosure have the space for bigger capacitors? Comparing sizes: And 3000F ones are around 140 mm in length. Thanks again. Got a second kCap instead. Will connect 2 kCap in parallel. A single kCap at the moment calibrates at around 1300 A and welds at around 1200 A.
  12. Q

    kWeld - "Next level" DIY battery spot welder

    This does not explain anything. Page 8 / 464: Description - yes, but Schultz describes it as well. There are at least 2 documents that do some practical explaination of the matter: The Effects of Polarity on the Resistance Welding Process Fundamentals of Small Parts Resistance Welding (no...
  13. Q

    kWeld - "Next level" DIY battery spot welder

    I'm interested in having only the base board of kWeld Pro, since I already have capacitors like the pictured ones. But here, I also have a question regarding kCap: Is it possible to add capacitors to existing kCap, or replace the existing ones? Main concern is whether the balancing circuit...
  14. Q

    DeWalt 20V Max 3.0Ah Battery Pack Teardown & Analysis

    Schematics of some DeWalt batteries: U1 is probably BQ7716 or BQ7718
  15. Q

    DIY Arduino timed spot-welder, FET-switched, adj. pulse

    Found this one: "Battery flux Resistance welding copper spot copper flux" https://www.aliexpress.com/item/1005002826064340.html ---------- Tungsten electrodes - I plan on testing this, since they are readily available in various rod diameters for TIG welding. Molybdenum - I can only find 8 mm...
  16. Q

    DIY Arduino timed spot-welder, FET-switched, adj. pulse

    Have you ever considered Tungsten or Molybdenum electrodes? Commercial spot welders use this type of electrodes for welding copper, for example: _nWJQIrbI_g
  17. Q

    DIY Arduino timed spot-welder, FET-switched, adj. pulse

    Thank you. :thumb: So, this is actually some sort of a Silver Brazing paste, for example: https://www.brazing.com/Products/silverBrazingAlloys This means the process with this paste is Resistance (Silver) Spot Brazing, not Resistance Spot Welding. They have 3 examples in the patent...
  18. Q

    DIY Arduino timed spot-welder, FET-switched, adj. pulse

    What is this compound, that you call a "flux" on the 3rd picture? "welding copper with flux" I looks like some sort of epoxy or silicone. Next, on the 2nd picture, there is a device between the positive and the negative electrodes. Is it a TVS diode? If not a secret, what it is?
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