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Principle of Spot Welding

Our welder's Capability

How-To-Use Our welder

Welding Stainless Steel

Thermocouple Welding

Welding with Nickel Plates

Welding with Metals
e.g. Aluminum, Steel, Phospate Bronze

Product Comparison

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Spot Welder HSW-01A

Spot Welder HSW-02A

Spot Welder HSW-03

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Nickel Plates

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F A Q (General)

FAQ(Technical)

HSW SERIES SPOT WELDER PRODUCT COMPARISON

Junction condition depends a lot on the metal types and the electrodes, and also on the plunge pressure of the electrodes. All comparison tables and data do not guarantee that the model concerned can weld as well as mentioned. Please use this as reference only.

LINKS ON THIS PAGE

 

    HSW- 01A   
    HSW- 02A   


Stainless Steel Wire

Diameter in mm
Stainless Steel Wire (Diameter in mm)
Stainless Steel Wire
(Diameter in mm)
 
0.5
0.9
1.2
1.6

0.5

AA
AA
AA
AA
0.9
 
AA
AA
A
1.2
 
 
A
B
1.6
 
 
 
B

*) Using stick electrode; the 1.6 mm ones are pre-processed.


Stainless Steel Wire

Diameter in mm
Stainless Steel Wire (Diameter in mm)
Stainless Steel Wire
(Diameter in mm)
 
0.5
0.9
1.2
1.6

0.5

AA
AA
AA
AA
0.9
 
AA
AA
AA
1.2
 
 
AA
AA
1.6
 
 
 
A

*) Using stick electrode; the 1.6 mm ones are pre-processed.


Stainless Steel Plate

 
Stainless Steel Plate (Thickness in mm)
Stainless Steel Plate
(Thickness in mm)
 
0.1
0.3
0.5
0.1
AA
 
0.3
 
 
0.5
   

*) Using HSW-W2 Picture on strength evaluation


Stainless Steel Plate

 
Stainless Steel Plate (Thickness in mm)
Stainless Steel Plate
(Thickness in mm)
 
0.1
0.3
0.5
1.0
0.1
AA
AA
AA
 
0.3
 
AA
AA
 
0.5
 
 
A
1.0
     
B

*) Using HSW-W2 Picture on strength evaluation

Stainless Mesh

  Diameter (mm) / line / cm
Diameter
(mm)
/ line / cm
 
0.15/13
 
0.15/13
 
 
 
 
 
 
 

*) More of the test result will be printed out soon..

 

Stainless Mesh

 
Diameter (mm) / line / cm
Diameter
(mm)
/ line / cm
 
0.15/13
 
0.15/13
AA
 
 
 
 
 
 

 

 

  LEGEND
AA
The junction strength needed for practical things is mechanically and electrically acquired.
A
It is mechanically jointed, but the junction strength is weaker compared to AA.
B
It is electrically jointed, but there is a possibility of breaking down. Additional fixation would make it usable.
C
Cannot be jointed. It will break if it falls from 1 m height.

Steel Plate (Iron) (SS・SK)

(Thickness in mm)

SS0.23

SK0.4
SK0.5
SS Steel 0.23
B
 
 
SK Steel 0.4
 
C
 
SK Steel 0.5
   
C
Stainless steel 0.1
A
   

*) Are still being tested.

Steel Plate (Iron) (SS・SK)

(Thickness in mm)

SS0.23

SK0.2

SK0.3

SK0.4
SK0.5
SS Steel 0.23
AA
   
 
 
SK Steel 0.2
 
AA
     
SK Steel 0.3
   
AA
   
SK Steel 0.4
 
   
AA
 
SK Steel 0.5
       
A

*) For SS Steel 0.1mm, HSW-PC1 was used.

 

Welding Different Metals To
S50C, SS400, SKD11 Steel Blocks

Type / Thick (mm)
Steel Block (16x60x60mm)
Copper Plate
0.2mm
C
Copper Wire
0.2mm
AA

☆ The width of the plates welded were 3.2 mm.

*) The strength of the junction above is not evaluated, but it is assumed to have the strength required.

 

Plating Steel Plate

(Thickness mm)

Tin 0.15

Zync 0.3
Tin 0.15
 
 
Zync 0.3
 
C

*) Are still being tested.

Plating Steel Plate

(Thickness mm)

Tin 0.15

Zync 0.3
Tin 0.15
AA
 
Zync 0.3
 
C

*) Tin : heavy steel plate Zinc : galvanized steel plate

 
Aluminum Foil

Type / Thick mm
Aluminum Foil 70μm
Aluminum Foil 100μm
Aluminum Foil 220μm
Aluminum Foil 70μm
AA☆
   
Aluminum Foil 100μm
 
AA
 
Aluminum Foil 220μm
 
 
A

 

HSW- 01A
HSW- 02A


Thermocouple

Diameter mm
 
Note
Chromel - Alumel center diameter 0.32 mm
AA
Power Controller HSW-PC1 was used
Copper - Constantan center diameter 0.32 mm
AA
Power Controller HSW-PC1 was used
Copper - Constantan center diameter 0.1 mm
AA
Power Controller HSW-PC1 was used

*) Power Controller HSW-PC1
and welding pinset HSW-W2 were used.
☆Copper - Constantant 0.1 mm Pictures (2007.10.30)


Thermocouple
New

Diameter in mm
0.32
0.1
0.1 and
0.025
0.025
Note
Chromel - Alumel
AA
AA
AA
AA
*1
Copper - Constantan
AA
AA
   
*2

*1) For 0.32mm welding, Power Controller HSW-PC1 and
stick electrode were used.


*2) Other than 0.32mm, Power Controller HSW-PC1 and
thermocouple pinset HSW-TC1 were used.

 

*) For all thermocouple welding, the use of Power Controller HSW-PC1 and thermocouple pinset HSW-TC1 is recommended.

Battery and Nickel Plate

Battery / Lead
Nickel Plate
Copper Wire (mm)
HSW-N12
HSW-N25
HSW-N64
0.18
0.3
0.5
CR2032
(TOSHIBA)
B
 
 
AA
C
C
CR2025
(SONY)
AA
 
 
 
 
 

LR44
(GP)

AA※
 
 
AA
B
C
LR41
(GP)
AA※
 
 
AA
AA
C
eneLoop
(SANYO A)
A※
 
 
 
 
 
GP2500
(GP A)
AA※
HR-4/3FAU (SANYO)
AA※
CP-2400SCR
(SANYO)
AA※

 


Battery
and Nickel Plate

Battery / Lead
Nickel Plate
Copper Wire (mm)
HSW-N12
HSW-N25
HSW-N64
0.18
0.3
0.5
CR2032
(TOSHIBA)
AA
AA
 
AA
AA
AA

CR2025
(SONY)

AA
AA
 
 
 
 
LR44
  (GP)
AA
AA
 
AA
AA
AA
LR41
  (GP)
AA
AA
 
AA
AA
AA

eneLoop
(SANYO)
  ( 単3)

AA
AA
AA
 
 
 
GP2500
(GP A)
AA
AA
AA
HR-4/3FAU (SANYO)
AA
AA
AA
 
 
 
CP-2400SCR
(SANYO)
AA
AA
AA
 
 
 

The measures of Nickel Plate used in the table above :

Model
Thickness
Width
HSW-N12
0.08 mm
3.2 mm
HSW-N25
0.15 mm
3.2 mm
HSW-N64
0.15 mm
6.4 mm

 

 

 

LEGEND

AA
The junction strength needed for practical things is mechanically and electrically acquired.
AA※
Additional undercut on the nickel plates is needed to achieve the same result as AA.
A
It is mechanically jointed, but the junction strength is weaker compared to AA.
B
It is electrically jointed, but there is a possibility of breaking down.
C
Cannot be jointed.
 

Battery and Phosphor Bronze Plate

Phosphor Bronze Plate
0.15 mm
0.2 mm
Alkaline A Battery
AA
A
Alkaline AA Battery
AA

Strength Evaluation Pictures

 

Battery and Stainless Steel Plate Battery and Stainless Steel Plate
Stainless Steel Plate
0.1 mm
0.2 mm
LR44  (GP)
AA
 
Stainless Steel Plate
0.1 mm
0.2 mm
LR44  (GP)
AA
AA
HSW- 01A
HSW- 02A
 
Platinum and Brass Wire

Wire Type / Diameter mm
Platinum Wire 0.3 mm
Note
Platinum Wire 0.3 mm
AA
Power Controller HSW-PC1 was used.

Wire Type / Diameter mm
Brass Wire 0.5 mm
Note
Brass Wire 0.5 mm
AA
Power Controller HSW-PC1 was used.
 

 

Copper and Stainless Plate

Plate Type / Diameter mm
Stainless Plate 0.1 mm
Note
Copper Plate
0.15mm
A
Stick Electrode HSW-EB1 and HSW-PC1 were used.
 
Different Kind of Metals

Type / Diameter mm
Stainless Steel
0.2 mm
Brass
0.2 mm
Bronze
0.15 mm
Nickel
0.15 mm
AA
AA*1
AA*3
Nickel
0.08mm
AA
AA*1
AA*3
Stainless Steel
0.2 mm
 
AA*2
A

Plate Type / Diameter mm
Stainless Plate 0.1 mm
Note
Copper Plate
0.15 mm
A
*4

Stick Electrode HSW-EB1 was used.

[ Welding Electrodes and Piling Order ]
*1) Stick Electrode - Nickel - Brass - Welding Pen
*2) Stick Electrode - Stainless Steel - Brass - Welding Pen
*3) Stick Electrode - Nickel - Copper - Welding Pen
*4) Stick Electrode - Stainless Steel - Copper - Welding Pen


 

Welding different kind of metals to
S50C, SS400, SKD11 Steel Blocks

Type / Thickness mm
Steel Block (16x60x60mm)
Copper Plate
0.2 mm
C
Copper Plate
0.2 mm
AA

*) The strength of the junctions above are not evaluated.

HSW- 01A
HSW- 02A
   
Spot-Welded Junction's Tensile Strength Evaluation
[ ABOUT THE EXPERIMENT AND HOW TO READ THE DATA ]

This experiment is conducted in order to know how strong is mechanically a welding junction welded with HSW Series. The strength value of a welding junction is affected by a lot of factors, so please use this as reference only.

The test pieces (experiment materials) are shown in the right picture. At the welding junction on the right, the right L-shaped part will be fixed using a vise. On the left side of the test piece, loops will be made and will be fixed with spot welding. The loop part, since it is a part to hang the hook of the spring balance for measurements, it will be different from the evaluated part; forces other than the ones on the shear direction will also work. Using the same load the test was done three times, and only if the results were the same for at least two times will the results be posted here.

Based on these strength evaluation results, the AAABC value of the product comparison on the upper half of this page is decided.
AA means enough strength mechanically; for junction between metals, it means it can hold more than 20kgf of load. Also, for battery, it means it can hold more than 5kgf.
A means about half of AA in strength. It is not sufficient, but even at this level it is usable for some purposes.
B means it will not break down if it falls from about 2m height to a concrete floor, and it cannot hold more than 3kgf. It still can be used for temporary fixation such as soldering, and also for parts that need temporarily electrical connectivity and do not being applied to external forces.
C means it will be joint temporarily, and it will break down if it falls from about 2m height to a concrete floor.

HSW- 01A

HSW- 02A

Stainless Plate (0.3 mm thick)
Stainless Plate (0.5 mm thick)
Stainless strip test piece.
Stainless strip test piece.
[ Experiment Materials ] Stainless Plate 0.3 mm thick 10mm wide
[ Machine Used ] HSW-01A and HSW-W2
a maximum 25 kg of a spring balance
[ Welding Method ] pile up 5 mm and weld in 4 points
[ Power Settings ] Standard Power Supply

[ Experiment Materials ] Stainless Plate 0.5 mm thick 10mm wide
[ Machine Used ] HSW-02A and HSW-W2
a maximum 25 kg of a spring balance
[ Welding Method ] pile up 5 mm and weld in 2 points
[ Power Settings ] Standard Power Supply with maximum pulse width

[ RESULT ]

 
LOAD
APPLIED TIME
CONDITION
1
5 kgf
30 mins
 no change (continued to 2)
2
10 kgf
60 mins
 no change
3
12 kgf
12 hours
 no unusual conditions up to 20kg
Stainless strip test piece. Spot sign appeared on the surface.Stainless strip test piece. Spot sign appeared on the back side
The front and the back of the test piece's welded section.
Strength test using spring scale.

[ RESULT ]

 
LOAD
APPLIED TIME
CONDITION
1
7 kgf
30 mins
 no change (continued to 2)
2
14 kgf
30 mins
 no change (continued to 3)
3
20 kgf
6 hours
 no unusual conditions

Spring scaleStrength test.

 


 

 

HSW-01A
HSW-02 (PREVIOUS MODEL OF 02A)
Stainless Steel Plate (0.5 mm thick)
Battery and Nickel Plate (shear direction)
Cannot find spot sign but withstand 8kgF.Broken strip by the strength test.
スポット痕はほどんど無いが、8kgまで耐えた
Strength test.

[ [Experiment Date ] October 29th, 2007
[ Machine Used ] HSW-01A + HSW-W2
[ Experiment Materials ] SUS 0.5mm - SUS 0.5mm in thickness
[ Result ]

 
LOAD
APPLIED TIME
CONDITION
1
5 kgf
90 mins
 no change (continued)
2
8 kgf
 
 break off


[ REQUIREMENTS ] Weld unto C size NiCad battery’s negative electrode a HSW-N25 (width 3.2mm x 0.15 thick nickel plate) using the welding pen (included in the standard pack), and afterwards weld a stainless line 0.9mm in diameter unto the nickel plate in three points, which will be the test piece. (Click the picture to zoom in)
HSW- 01A
[ Measurement ] The load is hung on the shear direction of the spot junction using a normal spring balance.
Stainless Plate (0.5 and 0.1 mm in thickness)
Stainless strip test piece.

剪断図

Spring scale.

[ [Experiment Date ] October 29th, 2007
[ Machine Used ] HSW-01A + HSW-W2
[ Experiment Materials ] SUS 0.5mm - SUS 0.1mm in thickness are piled up and welded in two points
[ Result ]
 
LOAD
APPLIED TIME
CONDITION
1
10 kgf
180 mins
 no change (continued)
2
20 kgf
4 hours
 no unusual conditions
Read out 7kg
  [ Result 1 ] The junction can hold 7 kgf for 5 minutes, and there are no unusual conditions in the junction part.
 
Read out 9.2kg
  [ Result 2 ] After holding 7 kgf for 5 minutes, the weight is slowly increased, and at 9 kgf the spot junction between the battery and nickel plate broke down.
 
Test piece
  [ Result 3 ] Look at the nickel plate after breaking down. There was a trace of spot junction. (Click the picture to zoom in) There are no unusual conditions in the three points of stainless line and the stainless loop line.
 

[ Machine Used ]
  (1) HSW-02 and welding pen (included in standard pack)
((2) 25 kgf tensiometer

[ Test Materials ]
  (1) HSW-N25 (witdh3.2C0.15mm thick of Nickel plate)
  (2) Diameter 0.9mm of stainless line

 
 
HSW- 02A
 
Nickel Plates (shear direction)
 

Nickel Test piece.
Nickel plates 0.15mm in thickness are piled up and welded in two points
no unusual condition after adding up 10 kg for 10 minutes (at the middle part)
(the part connected to the tensionmeter shows a sign of breaking up)

[Machine Used ]

(1) HSW-02A and welding pinset (HSW-W2)
  (2) 25 kgf tensiometer

[ Test Materials ]
  (1) HSW-N64 (width 6.4 x 0.15 mm thick of Nickel Plate)

 

HSW- 01A
HSW- 02A
Phospor Bronze (0.2 mm in thickness)
Phospor Bronze Plate (0.2 mm in thickness)
strip test piece.
test piece on AA battery
[ Experiment Date ] November 4th, 2007
[ Machine Used ] HSW-01A and welding pinset (HSW-W2)
[ Experiment Materials ] Phosphor bronze 0.2mm in thickness welded in two points
[ Result ] (1) 8 kgf 60 mins OK
(2) broke up after adding up more than 10 kgf
[ Experiment Date ] October 29th, 2007
[ Machine Used ] HSW-02A and welding pen (included in standard pack)
[ Experiment Materials ] Phosphor bronze 0.2mm in thickness and A battery's negative electrode
[ Result ] (1) 5 kgf 90 mins OK
(2) broke up after adding up more than 8 kgf
 
Steel Plate (SS Plate 0.23mm in thickness)
 
test piece.
  [ Experiment Date ] November 4th, 2007
[ Machine Used ] HSW-02A and welding pinset (HSW-W2)
[ Experiment Materials ] SK Steel 0.23 mm in thickness is piled up with 5 mm and welded in two points
[ Result ] (1) 10 kgf 90 mins OK
(2) 20 kgf 120 mins no unusual conditions
 
Steel Plate(SK Steel 0.5mm in thickness)
  [ Experiment Date ] November 4th, 2007
[ Machine Used ] HSW-02A and welding pinset (HSW-W2)
[ Experiment Materials ] SK Steel 0.4 mm in thickness is piled up with 10 mm and welded in two points
[ Result ] (1) 10 kgf 90 mins OK
(2) 20 kgf 120 mins no unusual conditions
  [ Experiment Date ] November 4th, 2007
[ Machine Used ] HSW-02A and welding pinset (HSW-W2)
[ Experiment Materials ] SK Steel 0.5 mm in thickness is piled up with 10 mm and welded in two points
[ Result ] (1) 10 kgf 90 mins OK
(2) 20 kgf 90 mins no unusual conditions
HSW- 01A
HSW- 02A