The HFTD-500 is a 500 kVA hydraulic copper diffusion welding machine developed for large flexible copper busbars, laminated copper foil connectors and copper-nickel conductive components. It combines medium-frequency electrical heating with controlled hydraulic pressure to consolidate the required connection area without adding solder, brazing alloy or flux.
A four-column press structure guides the upper welding head during clamping, heating and pressure holding. The machine provides a reference single-cycle welding area of up to 200 × 200 mm and a maximum hydraulic force of 20 tonnes, making it suitable for copper assemblies that exceed the working range of smaller pneumatic diffusion welders.
The actual welding capacity depends on the copper volume, individual foil thickness, number of layers, bonded dimensions, surface coating and required finished thickness. Before confirming the HFTD-500, HAIFEI reviews the customer's drawing and conducts sample testing when necessary.
Send Your Copper Busbar Drawing
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
Main Technical Parameters of the Equipment
Item |
Model |
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structural style
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4-Pillar Hydraulic Cylinder Welding Workbench
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control method
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Frequency conversion inverter; Control system for Haifei copper welding machine
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Temperature measurement range
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Temperature range: 300–1200°C; repeatability accuracy: ±0.5%TH;temperature can be set and displayed on the touchscreen.
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Work environment temperature range
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5-45℃
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Pressure application method
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Maximum output pressure: 20 T; starting pressure: 0.5 T
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Workbench activity range
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150 mm; repeatability accuracy of press head positioning: ±0.05 mm
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Electrode installation area
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240mm*240mm
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Effective welding area
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200mm*200mm (the smaller the area, the faster the welding speed);(Customizable)
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Single-time welding area
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200mm*200mm (the smaller the area, the faster the welding speed)
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Range of welding materials
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Copper-copper welding, copper-nickel welding, hard copper-soft copper welding
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Welding material thickness range
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0.03-5mm
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Thickness range of the welded product
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0.5-25mm
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Welding Control Function
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1,Output frequency: 15–400 Hz;
2,It can program up to 64 welding specifications;
3,Programmable output I/O port: Features three programmable output stages for better compatibility with PLCs, robots, and other devices.Weld point counting function.
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defencive function
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System shutdown due to abnormal water flow alarm, abnormal current alarm, or abnormal pressure alarm.
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Data Storage Function
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The database stores production data (such as pressure, temperature, and time), which is readable, traceable, and compatible with the MES system.
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authority management
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The software implements a hierarchical managementsystem. Administrators can define and store product welding parameters (such as pressure,temperature, and time), while employees can only access these parameters
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contour size of the unit
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1519 mm × 1218 mm × 2094 mm (length × width × height)
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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.
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. |
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?
Wuxi Haifei Intelligent Equipment Co., Limited is one of the leading manufacturers and suppliers of copper diffusion welding machine in China. With abundant experience, we warmly welcome you to buy advanced copper diffusion welding machine for sale here from our factory. Quality products and reasonable price are available.
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