Insights
April 7, 2023 · 2 min read · Materials
Joining two metals is a critical process that requires a strong, precise bond for various industries, including aviation, aerospace, automotive, medical, and manufacturing. Traditional welding methods, such as arc, gas, and resistance welding, are widely used to achieve this, but percussion welding is a unique and effective alternative that is gaining popularity.
Chapter 01 / 04
What is Percussion Welding?
Percussion welding is a microwelding process that uses high-velocity impact and low pressure to join dissimilar metals. Unlike other welding methods that rely on heat to melt and fuse materials, percussion welding creates a bond through a controlled electrical discharge and a low-pressure collision of the materials. This results in minimal Heat Affected Zone (HAZ) and is ideal for welding dissimilar metals that have different melting points or cannot be welded using other methods.
Chapter 02 / 04
How Does Percussion Welding Work?
Percussion welding is a quick and efficient process that does not require filler materials or long exposure to heat sources. The process involves heating the surfaces of two metals to their melting point with a high-temperature arc and then fusing them together with low pressure to form a single weld piece. The entire process takes only milliseconds and results in strong, durable joints that are highly resistant to breakage. Here's how it works:
- The two metals are positioned with their weld points at a predetermined gap.
- An arc is produced between the materials to heat them.
- During the percussive phase, the materials reach their melting point and are joined together with low pressure.
- The two materials are welded together without filler material in a matter of milliseconds.
Want to see it on your parts?
Send samples and we'll run test welds before you commit.
Chapter 03 / 04
Percussion Welding Product Suite
The Percussion Welding system is designed to make this microjoining process possible. The system includes the 858 Percussion Welder, the 726 Bench Fixture, and the Percussion Weld Monitor. These three products work together to produce durable and precise welds every time. The 858 Front Panel allows for easy adjustment for accurate metal joining, while the 726 Bench Fixture can be adjusted on the X, Y, and Z axis to create complex welds. The Percussion Weld Monitor provides precise control and accurate data collection through waveform analysis. This system does not reduce metal hardness and produces consistent and reliable welds.
Chapter 04 / 04
Choose Percussion Welding for Your Microwelding Application
Percussion welding offers a quick and efficient solution for joining dissimilar metals when creating parts and components. Contact us today to learn how we can help with your next project.
Part of: Dissimilar Metal Joining
More on dissimilar metal joining
Dissimilar Metals Guide →FAQ
What is percussion welding?
A heat-plus-impact process for joining metals.
An electric arc supplies the heat, then a rapid mechanical movement forces the two materials together, forming a full metallic bond with no filler.
Do I need filler metal, solder or flux?
No. There's no filler, solder or flux, and no electrodes to wear out.
That means cleaner joints, less waste, and no consumables to buy.
How do I know if my materials can be welded?
Start with the Parameter Finder or the weld schedules table.
If your pair isn't listed, tell us your weld challenge. We'll reply with a straight answer about whether percussion welding is a fit, and how.
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