So it begins...... Battery spot welder

[sternwake]

I had done a bunch of infinite slot battery spot welds with copper Nichel sandwich, using 50ms pulses, and later concluded i had overlapped the positive terminals too much.

I went in with side cuts s to remove excess, and heard and felt a weld fail., and it looked like a good one.

I then tried a few more and cursefest ensued as i wound up not trusting any of them, and removed all of them. Some ok welds, many completely inadequate, and would have eventually failed had i ostriched and continued on.

The 'ok' welds were leaving little pinpricks of copper on the cell, but not tearing both copper and nickel. Having achieved such solid welds on test cell, the the same pulse duration and technique on DMEGC cells had me hunting for variables.

So many influencing variables, but i figure the test cell, i keot dremelling off the remnants of weld, and instead of ni kek llated steel can, the nickel was gone, increasing resistance, causing hitter spots, and stronger welds. also the micro scratches, reduced surface area, more resistance, more heat, better welds.

New cells with thick nickel plating, far less resistance using same settings=inadequate welds.
Another factor, is my 0.15m copper,, depending on where the digital calipers measure varies as much as 0.03 mm whjch maKes for poor consistency.

I roll of 0.1mm copper arrived, and it seems to be 0.08 to 0.09, and i tried that with 0.1 nickel plated steel at 60ms pulse on test cell , no slot, and it was too much power.. blowing through nickel steel, nkt welding.

I blunted the welding tips for more surface area, tried again and it looked and felt right, on the test cell.

I then tried it on Dmegc cells with 70ms pulse, and i coukd tell by feel it was right, but needed verification, and tried to lift and peel and roll the sandwich off.

So screw the infinite slot method, and being weeny about pulse duration.