Copper Diffusion Welding Machine

 

 

The equipment is mainly used for conductive copper components that need a compact terminal or joint area while maintaining controlled dimensions and repeatable electrical performance.

Laminated Copper Foils and Flexible Busbars

For a laminated flexible busbar, several copper foils are stacked and positioned in dedicated tooling. One or both ends are heated and compressed to form a consolidated terminal, while the remaining foil section retains the flexibility required for movement, vibration or assembly tolerance.

Machine selection depends on:

• Thickness of each copper foil
• Total number of foil layers
• Bonding length and width
• Required finished terminal thickness
• Hole positions and machining allowance
• Flexibility required outside the bonded area
• Mechanical and electrical acceptance criteria

Both the individual foil thickness and the total stack structure must be provided. Two busbars with the same total thickness may require different process settings if their layer quantities are different.

 

Copper Braided Connectors

Copper braids may require end consolidation or joining to a copper terminal or solid busbar. Because the braided conductor can spread or move under pressure, the tooling must control its position and finished dimensions without damaging the flexible section.

Important information includes:

• Braid cross-sectional area
• Bare or tin-plated surface
• Braid width and thickness
• Required consolidated length
• Terminal material and dimensions
• Pull-force or bending requirement
• Cutting and end-forming process
• Required production quantity

Projects that also require automatic feeding, end squaring and cutting can be evaluated through Haifei’s copper braid processing solutions.

 

Solid and Laminated Copper Busbars

Larger copper busbars require uniform heating and pressure across the complete bonding area. Workpieces with similar external dimensions may still require different machines because of differences in overlap structure, material stiffness, joint area and heat dissipation.

For these projects, Haifei reviews the busbar cross-section, joint design, surface flatness, loading clearance, required force and electrical test method before recommending equipment.

 

Plated Copper and Copper-Nickel Parts

Selected tin-plated, nickel-plated or copper-to-nickel conductive components can be evaluated. Coating material and thickness can affect surface preparation, heating behaviour and bonding consistency.

A process developed for bare copper should not be transferred directly to a plated workpiece without sample verification.

 

 

Haifei copper diffusion welding machines can be used for different conductive copper parts, especially components that require stable bonding, low contact resistance and large-area joining.

 

 

Common copper parts include:

• Copper busbars
• Copper battery connectors
• Laminated copper foils
• Flexible copper connectors
• Copper braided connectors
• Copper conductive plates
• Copper-nickel conductive parts
• Transformer copper leads
• Switchgear conductive parts
• Energy storage copper busbars
• Power distribution copper connectors

For multi-layer foil parts, large copper busbars or copper-nickel conductive parts, sample welding is recommended before final machine selection.

 

 

Items \ Model	unit	HFTD-100-Q	HFTD-150-QY	HFTD-200-Y	HFTD-350-Y	HFTD-600-Y
Rated capacity	KVA	100	150	200	350	600
Power supply	V/Ø/Hz	380V±10% / 3 phases / 50Hz
Rated duty cycle	%	50%	50%	100%	100%	100%
Primary current Max.	A	100	200	300	400	800
Primary cable	mm2	3*25+2*16	3*30+2*16	3*50+2*16	3*70+2*16	3*150+2*16
Short-circuit current Max.	KA	35	40	42	58	100
Secondary voltage	V	9	9.7	10.4	13.8	13.8
Air pressure cylinder	Ø*L	Ø160*120/ Ø125*80	/	/	/	/
Hydraulic cylinder	Ø*L	/	/	Ø120*250	Ø120*250	Ø120*250
Working pressure Max. (0.5/10.5MPa)	KN	80	100	160	200/400	200/400
Cooling water demand	/	0.2～0.3MPa,40 micron filtration, Resistivity of 5 kΩ. cm
Cooling water consumption	L/Min	25	40	150	240	400
Throat depth	mm	425	320	320	320	320
Distance between copper plates	mm	248	267	340	340	340
Working environment	/	temperature: 1～45℃ humidity: 35～90％

 

 

Haifei provides pneumatic, hydraulic and servo-controlled equipment for different copper connector structures. The following comparison explains the general selection direction; the final configuration should be confirmed through drawing review and sample testing.

 

Compare the Available Machine Configurations

 

Machine type	Recommended use	Main considerations
Pneumatic	Smaller copper parts and limited bonding areas	Requires stable compressed air and a force requirement within the cylinder range
Hydraulic	Multilayer copper foils, larger busbars and wider bonding areas	Provides higher, stable pressure for thicker stacks and heavy-duty production
Servo-controlled	Precision parts, multiple recipes and automated production	Supports programmable movement and project-specific force or displacement monitoring
Customized system	Non-standard workpieces or complete production lines	Can integrate dedicated tooling, loading, welding, cooling, unloading and data functions

 

Customized Copper Welding Systems

For non-standard parts or higher production volumes, HAIFEI can customize:

• Graphite electrodes and positioning fixtures
• Extended working platforms
• Hydraulic or servo pressure systems
• Robot loading and unloading
• Automatic product positioning
• Conveyor connections
• Recipe and product identification
• Process-data collection
• Cooling systems
• Safety guarding and interlocks

The final scope is determined from the workpiece drawing, representative samples, required cycle time and technical acceptance conditions.

 

 

Send Your Requirement

 

 

 

Machine capacity cannot be selected from the copper part width or KVA rating alone. To recommend a suitable configuration, HAIFEI needs the following information:

 

Information required	Details to provide
Material	Copper grade, hardness, supplier specification and surface coating
Workpiece structure	Copper foil, braid, solid busbar or combined assembly
Layer information	Single-layer thickness, number of layers and total stack thickness
Joint dimensions	Bonding length, width and required finished thickness
Acceptance criteria	Pull, peel, bend, contact resistance or other test requirements
Production requirement	Parts per shift, number of models and preferred loading method
Factory utilities	Voltage, frequency, compressed air and cooling-water conditions

 

 

 

Send Your Workpiece Information

 

 

 

 

 

 

A typical copper diffusion welding process includes the following stages:

1. Surface Preparation

Oil, oxide, coating residue and burrs are removed from the joint area. The cleaning method used during production should remain consistent with the method approved during sample testing.

2. Stacking and Positioning

Copper foils, braids or busbar components are arranged according to the drawing and placed in dedicated tooling. Accurate positioning helps control terminal dimensions and prevents layer movement.

3. Initial Pressurization

The tooling closes and applies the programmed force across the joint area. Insufficient pressure can leave gaps between layers, while excessive pressure may cause unwanted deformation.

4. Electrical Resistance Heating

Controlled current passes through the configured heating circuit and raises the joint area to the required process condition. Heating output and time are matched to the copper structure, bonding area and tooling.

5. Pressure Holding

The workpiece remains compressed during the programmed holding period. Heating, pressure and holding time must be adjusted as a complete process rather than as unrelated settings.

6. Controlled Cooling

The part is held in the tooling during cooling to maintain dimensional stability. The machine cooling circuit must provide suitable water temperature and flow during repeated production.

7. Unloading and Inspection

After the tooling opens, the part is removed manually or automatically and inspected according to the agreed dimensional, mechanical and electrical requirements.

 

 

 

 

Get a Free Quote！

 

 

Wuxi Haifei Intelligent Equipment Co., Limited is well-known as one of the leading diffusion welder for copper manufacturers and suppliers in China. Please rest assured to buy high quality diffusion welder for copper made in China here from our factory. For price consultation, contact us.

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