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Welding Copper Wire to Nickel Plated Copper Ring

April 24, 2009

I am trying to weld a copper wire to a nickel plated copper ring. I currently ultrasonically weld copper wire to a copper ring, but a different application is requiring me to weld copper wire to the same copper ring, however, it is being nickel plated first. The hardness of the nickel plating does not allow for a good ultrasonic weld and parts routinely have to be soldered post welding to help improve strength.

I am looking into resistance welding with a brazing material. Does anyone have any suggestions as to what kind to use. I have been told a Sil-Fos material will work, however, I'm not sure which alloy of Sil-Fos. Or could there be another material or method I should use?

The wires must be welded post nickel plating and the strength of the bond is an issue, regular solder isn't strong enough.

Regards

Steve Kruse
Engineer - Kokomo, Indiana
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