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What is Micro Welding?
When you need a tiny little weld in just the right place, you need a micro welder. A micro weld spot may be as small as 0.02mm in diameter and connecting metals as thin as 0.007mm.
Who needs a weld that small?
The list of industries that utilize micro welding is just as wide as it is long. Aerospace companies, medical device manufacturers, oil and gas crews, renewable energy companies, battery builders, electronics, filtration manufacturers, electric motors and coils, lighting—the list goes on and on.
As a welder, the better you understand the micro welding world, the better the chance you can add micro welding to your list of services and grow your business. Let’s start by looking at the four types of technology that can deliver a tiny little weld in a very precise location.
1. Pulse Arc (or TIG)
Pulse arc welding is a plasma discharge welding process. Each plasma discharge creates a small weld and is precisely delivered thanks to 5x microscopic optics. Pulse arc welding only requires little energy to create the weld. Every aspect of the weld is digitally controlled. As a result, heat sensitive pieces can be joined with a low chance of thermal damage and the manner in which the metals are joined is also carefully controlled.
2. Fine Spot Micro Resistance Welding
Resistance welding, sometimes called spot welding, is an economical and proven welding process. Chances are you have a spot welder in your shop. With micro welding, it’s the spot size that attracts so many different industries. High volume production and automation capabilities means one or more welders can be integrated into a production line. Like pulse arc technology, every aspect of the weld is controlled digitally.
3. Thermocompression Micro Welding
Thermocompression welding uses specially designed electrode to provide the highest degree of precision of any micro welding technology. This electrode is bonded in a way that allows the two halves to remain isolated. When finely controlled energy is applied to the electrode, the tip heats for the duration of the weld, allowing the piece to heat without pass-through energy. Thermocompression micro welding is common for welding small coated or magnet wires. Welding to PCB boards, traces, and components is possible using thermocompression welding.
4. Laser Micro Welding
Laser welding technology uses collimated light to melt and fuse metals. Laser welding is ideal for automation and areas where joints are more difficult to reach. Heat in a laser weld is highly focused and does not affect the surrounding area. The operator usually holds the work piece using a bare hand while welding. Perhaps one of the key advantages of laser welding is the repetition capabilities: Up to 60 welds per second!
How to Put Micro Welding to Work for You
The world is full of micro welding opportunity. Technology is shrinking work pieces and manufacturers need the assistance of micro welding experts. And that expert could be you!
To help you find the next opportunity for your shop, take the Micro Welding Application Tour, a seven-step discovery series that’s sure to create an idea or two. Each discovery series only takes one or two minutes to watch a quality application sample video, but is sure to broaden your vision.
FREE T-shirt Just for Watching
Those who finish the seven-step discovery series receive a FREE micro welding application tour t-shirt! Only a limited number of shirts are available. Start today to secure your t-shirt.