Spot Welding Aluminium

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cheapcookie   10 W

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Spot Welding Aluminium

Post by cheapcookie » Jul 12 2017 10:33pm

Hey can some one explain to endless sphere what it would take to spot weld aluminium to aluminium ?

kdog   10 kW

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Re: Spot Welding Aluminium

Post by kdog » Jul 12 2017 10:38pm

A lot of surface prep, speed and lots of amps. If you thought copper was hard...

cheapcookie   10 W

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Re: Spot Welding Aluminium

Post by cheapcookie » Jul 12 2017 10:49pm

harder than copper ?

In some videos on youtube,
they put thin sheet steel sandwiching the aluminium and the electrodes, why is that ?

kdog   10 kW

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Re: Spot Welding Aluminium

Post by kdog » Jul 12 2017 11:29pm

Dunno, maybe they needed it. If it was purely for welding it would make it easier bc the steel would create heat and fuse. The power needed to weld .1mm cu didn't even come close to sticking .1mmAl. ( just a polish n clean for surface prep) Maybe some alloys of Al might work ok. Look into it for us!

Hillhater   100 GW

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Re: Spot Welding Aluminium

Post by Hillhater » Jul 16 2017 7:38pm

from the DIY plating thread..
A Sunstone welding video..
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cheapcookie   10 W

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Re: Spot Welding Aluminium

Post by cheapcookie » Jul 16 2017 8:08pm

I have seen this vid before where does that leave us??

Hillhater   100 GW

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Re: Spot Welding Aluminium

Post by Hillhater » Jul 16 2017 8:35pm

cheapcookie wrote:Hey can some one explain to endless sphere what it would take to spot weld aluminium to aluminium ?
Well,...the short answer is...what it would take is a spot welder !
....and a little practice ! :wink:
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Chalo   100 GW

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Re: Spot Welding Aluminium

Post by Chalo » Jul 16 2017 8:50pm

cheapcookie wrote:harder than copper ?
Aluminum has a higher specific heat capacity than copper (though it's lower per volume due to copper being three times as dense). Its thermal conductivity is close to, but lower than, that of copper. Aluminum forms a tenacious oxide skin from exposure to air, which makes it difficult to wet when welding. You have to scour the surface off, and not dilly-dally getting it welded after cleaning it.
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kdog   10 kW

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Re: Spot Welding Aluminium

Post by kdog » Jul 17 2017 1:55am

Bear in mind that in the sunstone vid they are welding with opposing electrodes- it's far easier, and that Al is super shiny. How much prep was omitted from the actual vid. I might try having a quick crack at welding some thin sheet lying around my shed. I'll be using opposing electrodes so it's not really going to be that deterministic, I'm already conceding defeat for use on cells.

Hillhater   100 GW

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Re: Spot Welding Aluminium

Post by Hillhater » Jul 17 2017 2:41am

the Sunstone vid was using a single pressure activated electrode , but yes its not the same as the dual electrode welding we need for cells..
Image
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jonescg   1 GW

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Re: Spot Welding Aluminium

Post by jonescg » Jul 17 2017 2:58am

Well I just tried welding 0.3 mm Nickel and got nowhere. 200 Joules did nothing... Solders beautifully though ;)

cheapcookie   10 W

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Re: Spot Welding Aluminium

Post by cheapcookie » Jul 17 2017 11:38am

jonescg wrote:Well I just tried welding 0.3 mm Nickel and got nowhere. 200 Joules did nothing... Solders beautifully though ;)
Can you try with alu from a soda can ?

Prepped nicely it could make for a nice supply of alu

Hillhater   100 GW

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Re: Spot Welding Aluminium

Post by Hillhater » Jul 17 2017 5:44pm

Al from soda/beer cans is 100% coated with prtective epoxy laquer..both sides.. So a lot of prep will be required. :o
And the thickness is less than 0.1mm in the side walls, or 0.25 mm in the center of the bottom "dome"
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Re: Spot Welding Aluminium

Post by amberwolf » Jul 17 2017 6:55pm

Hillhater wrote:Al from soda/beer cans is 100% coated with prtective epoxy laquer..both sides..
some interesting info on that
https://www.wired.com/2015/03/secret-li ... rn-marvel/

Hillhater   100 GW

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Re: Spot Welding Aluminium

Post by Hillhater » Jul 17 2017 10:29pm

..An interesting article,
...... the first thing I learned there was that manufacturing aluminum cans is so challenging, and requires such a vast amount of study, design, and precise machining, that many consider cans the most engineered products in the world.
but as a lifelong "canmaker" , i have to say its only a very superficial glimpse of the full story..
EG.. aluminium cans are relatively easy to make compared to the electo coated steel ones that are equally common inEurope.
One detail relavent to us here is that can manufacturing technology was the basis that battery manufacturers adopted to produce the casings for all those "D", ,"C" , "AA" etc etc primary cells, and also the shells for 18650 cells and similar.
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Hummina Shadeeba   1 MW

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Re: Spot Welding Aluminium

Post by Hummina Shadeeba » Jan 13 2018 2:53am

adding another higher resistance material in a spot welding sandwich maybe creates the heat needed to do the most conductive materials: http://bbs.homeshopmachinist.net/thread ... pot-welded

999zip999   100 GW

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Re: Spot Welding Aluminium

Post by 999zip999 » Jan 14 2018 11:45pm

You can also compress them between two plates with nuts bolts rivets exedra with a conductive paste. What are you using for and at how many amps what are the cells what chemistry what's going on here. Could be paper clips or a laser welder ?

Hummina Shadeeba   1 MW

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Re: Spot Welding Aluminium

Post by Hummina Shadeeba » Feb 04 2018 12:37am

Hillhater wrote:
Jul 17 2017 5:44pm
Al from soda/beer cans is 100% coated with prtective epoxy laquer..both sides.. So a lot of prep will be required. :o
And the thickness is less than 0.1mm in the side walls, or 0.25 mm in the center of the bottom "dome"
eww. i thought Coke was acidic enough to eat through stuff, why arent we all drinking epoxy?

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