Is Percussion Welding Right for Your Joint? Checklist

Checklist

Tick what applies. Your fit score updates live, and an engineer can confirm it with test welds.

I need to join two different metalsCopper to aluminum, Kovar to molybdenum, nickel to tantalum — dissimilar pairs are where percussion welding is strongest.
My parts are small: wire, pin or thin materialOur HAZ calculator covers roughly 0.1–2 mm material; typical work is fine wire and pin joints.
Heat-sensitive parts sit close to the weldArc heating lasts only milliseconds, so the heat-affected zone stays minimal.
Low electrical resistance across the joint mattersThe result is a direct metal-to-metal bond with near-zero electrical resistance.
The joint must survive shock, vibration or temperature extremesNo solder or crimp to fatigue. In pull tests the wire often breaks before the weld does.
I want no filler metal, solder or flux in the jointPercussion welding uses no filler, solder, flux or electrodes — cleaner joints, nothing to consume.
Today I crimp and solder, or my current welds are inconsistentA direct autonomous weld replaces the crimp-and-solder step.
I'll make enough parts to want a repeatable, automatable processThe process uses the same handling systems as other micro-welders and can be monitored good / no-good.

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.

Which metals can it join?

Dissimilar combinations are the specialty — aluminum, brass, copper, steel, titanium and many more.

Our lab database holds 131 tested weld schedules across 33 materials and 68 material pairs. Don't see yours? We've welded hundreds of combinations and can develop a schedule for yours.

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

Is percussion welding right for your joint?

Your questions, answered

Tell us your weld challenge