Direct resistance projection welding of copper and brass

Abstract

The present study discusses direct resistance projection welding of a multi-core copper cable to a discharge brass terminal. Resistance welding was carried out with a conventional machine. The upper tungsten electrode, which comes into contact with the multi-core copper cable, and the lower copper electrode, on which the brass terminal is lying during welding, are described. In the experimental research, the optimum welding parameters for direct welding (i.e.welding without an intermediate layer or a brazing filler material) of the two workpieces concerned were found. The welded joints obtained were subjected to a strength test, and metallurgical and resistance investigations. The strength test showed that the welded joint was quality welded and had higher strength than the brazed joint. With a heat resistance test during current conduction, it was found that the joint heated much less than the brazed joint. Metallographic investigations of macro-specimens and a chemical analysis at the copper/brass joining line are described.

Tribo-mechanical characterization of Cu-Cr-Zr ternary alloy aimed at fin-tube resistance welding electrode material

“…Presently, H-fin to tube welding is performed using a pair of electrolytic tough pitch (ETP) copper electrodes (Tušek et al , 2005; Xu et al , 2013). ETP copper is the most regularly used type of copper as electrical and electronic conductors.…”

“…Research on copper electrode for resistance spot welding has been carried out (Tušek et al , 2005; Xu et al , 2013). Lindero-Hernández et al (2019) investigated static contacts for copper–beryllium alloy C172 for high-current-density pulsed-power applications.…”