The Haifei Hydraulic Diffusion Welding Machine is specifically developed for large-area copper bonding applications where high clamping force, stable pressure holding, and precise process control are essential. Unlike traditional fusion welding methods that melt the base material, diffusion welding creates a solid-state metallurgical bond through the combined action of heat, pressure, and time. This process helps preserve the original characteristics of the copper material while producing a reliable electrical connection suitable for demanding industrial environments.
The hydraulic pressure system provides stable force output across large bonding surfaces, making it particularly suitable for heavy copper components, wide conductive assemblies, and applications requiring extended holding cycles.
Key Features & Benefits
Solid-State Bonding
No filler materials; metals fuse at atomic level without melting, preserving material properties.
01
High Strength & Precision
Produces joints with near-parent-metal strength, zero porosity, and minimal distortion.
02
Versatile Material Compatibility
Welds dissimilar metals (e.g., Cu-Al, Ti-Steel), superalloys, and composites.
03
Hydraulic Pressure System
Delivers uniform, high-pressure (up to 50MPa+) for consistent diffusion.
04
Automated Control
PLC/HMI interface for precise temperature (800–1200°C), pressure, and cycle time management.
05
Typical Products Manufactured Using Hydraulic Diffusion Welding
Laminated Copper Shunts
Laminated copper shunts are widely used in switchgear, transformers, battery systems, and industrial power equipment. These components often consist of multiple layers of copper foil that must be joined together while maintaining excellent conductivity and flexibility.
01
Transformer Copper Connectors
Power transformers require reliable conductive connections capable of operating continuously under high electrical loads. Hydraulic diffusion welding provides stable pressure throughout the welding cycle, supporting the production of transformer connectors with low resistance and consistent bonding quality.
02
Large Copper Busbars
As current carrying requirements increase, busbar dimensions often become larger and thicker. The hydraulic system is particularly suitable for large copper busbars because it can maintain stable force across the entire bonding area, reducing the risk of uneven bonding.
03
Railway Power Connectors
Rail transportation systems rely on robust electrical connections capable of withstanding vibration, thermal cycling, and continuous operation. Diffusion welded copper conductors are commonly used in railway power distribution equipment where reliability is critical.
04
Energy Storage Conductive Components
Energy storage systems require large conductive parts that can efficiently transfer electrical energy while minimizing resistance losses. Hydraulic diffusion welding supports the production of these components with stable quality and repeatable performance.
05
Specification and Parameters
|
|
Items \ Model |
unit |
HFTD-150-Y |
HFTD-200-Y |
HFTD-350-Y |
HFTD-600-Y |
|
1 |
Rated capacity |
KVA |
150 |
200 |
350 |
600 |
|
2 |
Power supply |
V/Ø/Hz |
380V±10% / 3 phases / 50Hz |
|||
|
3 |
Rated duty cycle |
% |
50% |
100% |
100% |
100% |
|
4 |
Primary current Max. |
A |
200 |
300 |
400 |
800 |
|
5 |
Primary cable |
mm2 |
3*30+2*16 |
3*50+2*16 |
3*70+2*16 |
3*150+2*16 |
|
6 |
Short-circuit current Max. |
KA |
40 |
42 |
58 |
100 |
|
7 |
Secondary voltage |
V |
9.7 |
10.4 |
13.8 |
13.8 |
|
8 |
Air pressure cylinder |
Ø*L |
/ |
/ |
/ |
/ |
|
9 |
Hydraulic cylinder |
Ø*L |
/ |
Ø120*250 |
Ø120*250 |
Ø120*250 |
|
10 |
Working pressure Max. (0.5/10.5MPa) |
KN |
100 |
160 |
200/400 |
200/400 |
|
11 |
Cooling water demand |
/ |
0.2～0.3MPa,40 micron filtration, Resistivity of 5 kΩ. cm |
|||
|
12 |
Cooling water consumption |
L/Min |
40 |
150 |
240 |
400 |
|
13 |
Throat depth |
mm |
320 |
320 |
320 |
320 |
|
14 |
Distance between copper plates |
mm |
267 |
340 |
340 |
340 |
|
15 |
Working environment |
|
temperature: 1～45℃ humidity: 35～90％ |
|||
Challenges in Large Copper Diffusion Welding
Producing high-quality copper diffusion welds becomes increasingly difficult as the size of the workpiece increases.
Pressure Distribution Across Large Areas
When bonding large copper surfaces, uneven pressure distribution can lead to incomplete bonding or inconsistent conductivity. Maintaining uniform force across the entire welding area is one of the primary challenges in large-scale diffusion welding.
Thermal Expansion and Deformation
Copper expands significantly when heated. If temperature and pressure are not properly controlled, deformation may occur, affecting both dimensional accuracy and bonding quality.
Surface Oxidation
Copper surfaces naturally oxidize when exposed to air. Oxidation can interfere with atomic diffusion and reduce bonding effectiveness. Proper surface preparation and process control are essential.
Long Holding Cycles
Large copper components often require extended heating and holding periods to achieve sufficient atomic diffusion. The pressure system must remain stable throughout the entire cycle.
How Haifei Solves These Challenges?
Stable Hydraulic Pressure System
The hydraulic system provides continuous force output throughout the welding process, helping maintain consistent contact conditions between copper surfaces.
Customized Tooling Design
Every workpiece presents unique challenges. Haifei designs customized fixtures and tooling systems based on the dimensions, geometry, and bonding requirements of each project.
Multi-Zone Temperature Control
Independent temperature monitoring helps maintain consistent heating across large bonding areas, improving process stability and product quality.
Process Development Based on Actual Samples
Rather than relying solely on theoretical calculations, Haifei develops welding parameters based on customer samples whenever possible. This helps ensure that the recommended process is suitable for the actual production environment.
Why Choose Our Machine?
As a professional manufacturer with decades of experience in diffusion bonding technology, we provide more than just a machine. We provide a complete production process, including mold design and parameter optimization, to ensure your products meet international standards.
Our hydraulic diffusion welders offer energy efficiency, repeatable quality, and customizable configurations (size, pressure range, automation level). With ISO-certified manufacturing and global clientele, we ensure reliability for high-value welding applications.
Certifications
40+ Patents and 2 National Software Copyrights, 10,000㎡ Factory with 100+ skilled employees.
Our Partners
We have served over 5,000+ customers worldwide, and our long-term partners include Tesla, BYD, and Siemens.Over 50+ Fortune 500 companies.
Haifei Client Site
FAQ
01.What is the principle of a Hydraulic Diffusion Welding Machine?
02.Why is diffusion welding better than traditional soldering for copper connectors?
03.What materials can be processed by this molecular diffusion welder?
04.Can the welding parameters be customized for different busbar thicknesses?
05.Is a cooling system required for the hydraulic diffusion welding process?
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