Having run into problems with Boss welder (link) I was stumped on how to carry on building my battery packs for my ATBs. It’s still my go-to soldering iron, there is much to love even though I would like to bring back it’s welding capability.
I suspect FET damage but there are no errors or visible signs, apart from weak welds even with high settings. It wasn’t always this way, I was very happy and able to weld nickel on top of copper even with a 3s 3Ah 65c Graphene which is ever so slightly swollen now.
A switch to 4S via 4 x 2s high discharge Turnigy hard case 5Ah 60-120c packs did not help. Nor a Turnigy Nano-Tech 4s 3.3Ah 70-150c…so it’s the welder(*) but do not know how to diagnose and fix.
Here’s the full kit along with my own not-so-great 3D print of the stl available, out of sight is a foot pedal which is included.
It was a fun, easy and relatively quick operation to put together with helpful documentation. One gotcha is that you should have a crimp tool to mate the 8AWG electrode wire to the electrode, I was lucky enough to have this one from Amazon which did quick work of it
The electrodes are a thing of beauty btw. You can keep your foot on the pedal which allows you to inspect the values of the weld you just performed such as energy used in the pulse in Joules, weld duration, amps used, resistance of weld, FET temp.
I’ll build up on this post some more in the coming days
Here is some 0.15 pure nickel @30 joules using the Nano-Tech, I’m still fine-tuning it. What I really love is the calibration and measuring of discharge, that is distinctly an advantage for consistency and problem tracing.
Here is a range of weld on a 5J range using fresh 0.2mm nickel on 0.15mm copper
Lets look closeup at the 45J weld as a deep but sane welding energy level
You can get this spot welder here, I think Frank may be able to work in a small discount code if someone need a push.
- Frank kindly provided a spare set of electrodes to perform a like-for-like test using the same electrodes/battery, more on this to come.