40
through the bottom layer (puncture the battery can) . In this case, a thinner layer of copper should be
selected .
ALLOYS
Some metal combinations produce weld results that are less than desirable .
•
Titanium to Stainless Steel leads to brittle welds .
•
Aluminum to Copper welds are often weak .
•
Aluminum to Stainless Steel welds can be brittle .
•
Copper to Copper welds can require a lot of energy and create a lot of heat in the components .
•
Most Brass welds are challenging because of the Zinc content causing uneven temperatures and
leaving soot upon evaporation .
•
Nickel can often be used as an intermediary layer between two metals that don’t work too well
together (i .e . aluminum to copper) .
Spring Force
•
Typically, 10-12lbs of spring force is ideal for performing welds .
•
The spring force may need to decrease if the parts are fragile and can’t withstand high forces .
•
The spring force may need to increase if a weld spot forms on the top layer, but the bottom layer
remains unaffected .
•
The spring force can also be lowered if weld cycle time needs to be reduced (the weld head won’t
need to take as much time to lower at the lower force ranges), but it is important to maintain some
pressure at the weld location for ideal results .
Orion 250i2 EV CNC Settings
Experimenting with weld parameters can be very educational and lead to a better understanding of
welding applications . Many different factors can have an effect on the way the welder will behave for
any given combination of settings (i .e . types of metal being used, thickness of metal, geometry of
components, gaps between mating surfaces, electrode size and shape, gauge of ground wire, argon
coverage, etc .) . For this reason it can be somewhat difficult to produce a fail- safe settings schedule that
will work every time .
The best way to find the correct settings for a given application is to start low in energy and increase the
settings incrementally until the welds are strong enough and have the desired texture/size . The weld
results can be tweaked by changing the various settings available .
