Free tool
Estimated heat-affected zone width
0.052mm
Compared with other methods (estimated)
What it means
For percussion welding of steel, the rapid energy input ensures a minimal HAZ. Ideal for maintaining mechanical properties in thin steel components. Robust and clean pin-to-plate connections.
Suggested applications: Battery terminals, structural micro-joins.
About this estimate. A simplified model for thin material (0.1–2 mm) that assumes a typical 50 J percussion weld energy and uses fixed material factors. Laser and TIG figures apply approximate ratios (×1.2 and ×2.5). It illustrates relative HAZ size; it is not a substitute for metallographic measurement on your parts.
Get this validated on your parts
Send us the details and an engineer will review your steel joint. Or see starting weld parameters.
FAQ
What is the heat-affected zone (HAZ)?
The area around a weld where the base metal isn't melted but its properties are changed by heat.
In precision joints a large HAZ can soften material, add resistance or distort parts, so smaller is better.
Why is the HAZ so small in percussion welding?
Heating lasts only milliseconds.
The rapid, localized energy discharge heats the interface, then the parts are forged together almost immediately, so little heat spreads into the surrounding material.
How accurate is this calculator?
It's a simplified estimate for thin material from 0.1 to 2 mm.
It assumes a typical 50 J weld energy and fixed material factors, so use it to compare materials and thicknesses, then validate on real parts. We can run test welds for you.
Which weld types does it cover?
Pin-to-plate, pin-to-wire, and pin/wire to pin/wire.
Think battery terminals and PCB connections, sensors and fine-wire assemblies, and component-lead joining.
Still have a question? Tell us your weld challenge and an engineer will reply.
Start here
Share what you're joining and what's going wrong. We'll tell you straight whether percussion welding is a fit.
Prefer to talk? Book a demo or call 303-536-7838