Easy Spot Welding Machine

Intro: Easy Spot Welding Machine

Simple and easy way to do spot welding at home.Watch full video for better understanding.

For YouTube Channel Link click here

STEP 1: The Thing You Want to Do Spot Welding To:- Lithium Ion Battery in My Case

First what you need is the thing to which you want to do spot welding to.

In this case ,i have used a lithium ion battery to which i am going to spot weld nickel alloy strips.

STEP 2: Nickel Alloy Strips for Lithium Ion Batteries Only:

You will need 2 of these strips for both the terminals of the battery.

STEP 3: Super Capacitor or Ultra Capacitor:

A low voltage high current source.In my case i have used a 2.7V 100F super capacitor which produces a maximum current of around 100 amperes.You can also use a 500F or above but it becomes difficult to the thing to which you are doing spot welding to from high current which melts the metals.

STEP 4: Thick Copper Conductors:

You will need 2 thick copper conductors that can withstand the high currents produced during short circuit.You can get these from copper shading ring induction motors that are no longer of use.Thin copper conductors won't work and will melt easily.

STEP 5: Multimeter

A multi-meter to measure the voltage rise when you are charging the super capacitor to their rated voltage.U have go disconnect the charger as soon as the capacitor reaches its rated voltage or it will burst open after abnormal heating.

STEP 6: Voltage Check:

Check the voltage of the super capacitor for the final time before doing spot welding.Make sure that it is fully charged.

STEP 7: Spot Welding:

Touch one copper rod to the battery terminal and the other to the nickel alloy strip and then touch the nickel alloy strip to the battery terminal.The circuit will complete making a short circuit and creating a heating point high enough to melt and stick the 2 metals to each other.

STEP 8: Spot Welding 2:

Repeat previous step to the other terminal of the battery as well.

STEP 9: Congrats:

You have successfully completed your first spot welding.

STEP 10: Charge Check:

You can also check the charge left in the capacitor and discharge it completely for safety purposes.

Comments

[countrywill]

Hi I would like to build this project but
would like to use two capacitors at 500F
2.7V as suggested by iffee (in your comments section) my plan would be to charge
the capacitors using a 5v mobile phone charger.

However I would like to add some sort of circuitry
that would do the following:

1 red LED to indicate the capacitors are
charging and go off when fully charged

1 green LED to indicate capacitors are
fully charged

And some sort of circuit that would disconnect the
charging circuit when capacitors are fully charged (possibly a relay)

Could you please advise if this is possible
and how I can accomplish this?

Thanks

Alf

[iffee]

Better arrangement:-
Use two 500F super capacitors in series and charge them with any 5 volts DC sources. That will give improved performance due to increased volts. Moreover you don't have to monitor or take care of the overcharging.

[jimmyf]

Well made. Thanks for sharing.

[omars2]

Thanks a lot jimmyf :)