The 600KVA Hydraulic Copper Diffusion Welding Machine is a high-power resistance diffusion welding system designed for joining copper busbars, copper braided connectors, laminated copper foils, and flexible copper connectors.
This machine combines heat, pressure, and atomic diffusion to create a solid-state metallurgical bond between copper materials. Unlike traditional welding processes, diffusion welding joins metals without melting them, producing a highly conductive and mechanically strong connection.
The 600KVA system is particularly suitable for large-area copper welding and multi-layer copper laminations, making it ideal for industrial production environments.
Built for Flexible Copper Busbars and Copper Conductors
Copper has excellent electrical and thermal conductivity, but this also makes it difficult to weld consistently. In large-area copper joining, heat can spread quickly, pressure may not be evenly distributed, and the welded area may suffer from weak bonding, high contact resistance, surface marks, or unstable quality between batches.
This copper diffusion welding machine is developed for conductive copper parts where both mechanical strength and electrical performance matter. It is especially suitable for:
Flexible copper busbars
Copper braided connectors
Laminated copper foil connectors
Copper soft bands
Copper busbar joints
High-current copper conductors
EV battery copper connectors
Power distribution copper assemblies
Instead of using filler materials or relying only on surface melting, diffusion welding forms a solid-state bond through controlled heat, pressure, and holding time. This helps create a cleaner and more stable connection for copper parts used in long-term electrical operation.
Why This Copper Diffusion Welding Machine Works for High-Current Copper Parts
Large-Area Copper Welding Capability
180 × 180 × 30 mm(Graphite can be heated to red-hot)
This makes it suitable for:
- Copper laminations
- Copper busbars
- Multi-layer copper sheets
Extremely Low Electrical Resistance
Diffusion welding produces a joint with resistance very close to that of the base material.
Benefits include:
- High electrical conductivity
- Lower heat generation
- Longer service life
No Filler Materials Required
Unlike brazing or soldering, diffusion welding does not require filler metals.
Advantages include:
- No flux contamination
- No porosity
- Cleaner weld structure
Suitable for Automated Production
The machine can support automated operations such as:
- Automatic pressure control
- Programmable welding cycles
- Parameter storage and recall
Example drawing 1 
Example drawing 2
Copper Diffusion Welding Machine System layout
| Serial Number | Description |
| 1 | Transformer |
| Continuous output current 45KA; imported raw materials, domestically assembled, durable, and high power output. | |
| 2 | Medium frequency welding controller |
| High-tech SM surface mount technology is used in the assembly line operation. | |
| 3 | Hydraulic cylinder |
| 4 | Infrared temperature detection system |
| 5 | Connecting copper plates,T-shaped copper platforms,and copper strips |
| 6 | Packaging and transportation |
| 7 | Installation and debugging |
| 8 | project management |
| 9 | On-site robot installation guidance, programming, and debugging |
| 10 | Customer on-site operator system training |
Overall machine parameters
| Model | Rated power: 600KVA Duty cycle: 100% | Continuous output currentI2p kA | Primary current A | Secondary voltage V |
Electrode pressure k N |
Cooling water flow rate L/min |
| HFTD-Y-600 | 600 | 45 | 400 | 13 | 20(Customizable) | 240 |
HFTD-Y-600 Configuration
The welding power supply is equipped with an operation panel, and the main unit is equipped with a start button,
an emergency stop button, etc.;
| 1 | Intermediate frequency diffusion controller | Main electronic components of the controller: German Semikron thyristors, metal film capacitors, Schneider circuit breakers, air switches, etc. The existing control motherboard adopts internationally advanced digital technology. |
| 2 | Transformer |
The weld resistance transformer adopts German technology and imported raw materials, with a magnetic permeability greater than 16000GS. The secondary winding is made of refined copper casting with internal circulation water cooling, and the primary winding uses specially made double glass fiber wrapped flat copper wire insulation, with an insulation class of B. The transformer has undergone voltage regulation and temperature rise test to ensure that it reaches the rated power at a load duty cycle of 100%, fully meeting the requirements of working strength and welding strength. |
| 3 | Hydraulic cylinder | Haifei, with a maximum pressure of 20t. |
| 4 | Structural components | The welded frame undergoes aging treatment, resulting in high strength and no deformation. |
| 5 | T-shaped copper platform, connecting copper structural components | High-quality copper materials, fine processing |
| 6 | Graphite mounting base plate | Chromium-zirconium copper (optional) |
| 7 | Other | Manual design, processing, assembly; management; testing; debugging; etc. |
Four-column structure of diffusion welding machine
Because the power industry has stringent requirements for flexible connections, demanding flatness and a firm grip, our diffusion welding machine adopts a four-column structure, resulting in more stable welding and higher precision.
The core component of the four-column structure
Support frame
A stable gantry system consisting of an upper crossbeam, a lower crossbeam (worktable), and four precision columns connected by nuts.
Movable crossbeam
Located in the middle of the four columns, it slides up and down along the columns via guide sleeves, used to transfer pressure to the welding workpiece.
Vacuum furnace body
Typically mounted on the lower worktable, with columns passing through or surrounding the furnace body. It integrates heating elements and heat shields internally.
Technical advantages of four-column structure
Stability under high pressure
Diffusion welding requires the application of high temperature and continuous pressure (uniaxial pressure) to induce atomic diffusion. The four-column design provides extremely high mechanical rigidity, capable of withstanding pressures of tens to hundreds of tons without significant deformation.
Superior guiding accuracy
The moving crossbeam runs along the four columns, ensuring high parallelism between the pressure head and the workpiece contact surface. This is crucial for uniform stress distribution in large-area, multi-layered stacks (such as PCHE microchannel heat exchangers).
Open working space
The four-sided open structure facilitates the installation of large furnace bodies and the loading and unloading of workpieces.
Suitable Copper Parts and Applications
Diffusion welding produces a near base-metal joint with extremely low electrical resistance, making it ideal for high-current electrical components.
EV Battery and Energy Storage Busbars
Power Distribution and Switchgear
Flexible Copper Connector Manufacturing
Industrial High-Current Conductors
The processed products can meet the performance requirements
Processing requirements for the products：
| Option 1 | Require |
| Pre-welding treatment | The product can meet all requirements without pre-welding activation or soaking treatment. |
| Welding Forming | The weld joint is formed in one operation, with no pressure weld marks or a smooth transition at the root of the weld. |
The processed products can meet the appearance requirements:
| Project | Require |
| Appearance |
1. No indentations or smooth transition at the weld root, no wrinkles in the soft band. 2. No arcing, melting, or blackening at any part of the weld. 3. No blistering or pitting on the weld surface. 4. Weld surface roughness Ra 3.2. 5. Weld formed in one pass, with no bulging in the soft band. |
Customer ROI
By investing in this Copper Diffusion Welding Machine, you gain:
Lower Rejection Rates
Eliminate voids and slag common in traditional methods.
Reduced Material Costs
No expensive silver solder or flux needed.
Enhanced Product Lifespan
Low-heat joints extend the life of your electrical assemblies.
Why Choose Haifei's Copper Diffusion Welding Machine?
Why Choose Our Machine ?
HAIFEI Intelligent Equipment specializes in the research, development, and manufacturing of resistance welding equipment and automated welding solutions.
Its product range includes diffusion welding machines, spot welding machines, seam welding machines, and automated welding equipment, which are widely used in industries such as new energy, electrical equipment, and automotive manufacturing.
01
16 years of experience in resistance welding equipment manufacturing
02
Serving well-known companies such as Tesla and Geely Auto
03
A complete system covering R&D, machining, assembly, and testing
04
Support for custom welding equipment and automated production lines
Our Partners
40+ Patents and 2 National Software Copyrights, 10,000㎡ Factory with 100+ skilled employees.
Certifications
We have served over 5,000+ customers worldwide, and our long-term partners include Tesla, BYD, and Siemens.
Over 50+ Fortune 500 companies.
Haifei Customer Site
FAQ
01.What is the maximum thickness this Copper Diffusion Welding Machine can handle?
02.Does the Copper Diffusion Welding Machine require a special cooling system?
03.Can I weld flexible copper busbars with this busbar welder?
04.How is the pressure controlled in this diffusion welding machine?
05.What copper parts can this copper diffusion welding machine weld?
06.Can the parameters be recorded for quality control?
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