Not trying to melt a hole through the nickel, the end of the can is already sagging when it welds (marks not visible under probe pressure alone)
How many J before the cells are at high risk of going poof?
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Higher than 100J, that is what I used to weld 0.3 nickel onto some 40Ts. All cells are alive and well.
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Have you tried using less probe pressure? You shouldnāt need to be that high power. What are your weld amps?
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Fair enough, Iāll try that this weekend then, not looking forward to grinding these down
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My best guess is this is like 5 lbs of force per probe? If I do less it doesnāt seem to stick at all but at 5 lbs it tacks in place
Last I checked it was around 1400A, I run a fan on the battery so itās not overheating
Weird, thatās pretty good welding current. Are your tips reasonably sharp?
Maybe a 2mm radius point?
Tips are cleaned with sandpaper, nickel and cans are cleaned with alcohol before welding
Have you cleaned the negative poles of the cells with a real cleaner instead of alcolhol? Alcohol is not very good at removing oils f.e.
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2mm radius is pretty round. Iād try sharpening them and recalibrating before pumping up the juice
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What would you recommend?
I sharpen them more than that but they wear down to that in a couple welds
Guess I gotta sharpen every 10 cells?
Lol i sharpen maybe every 10 packs 
I know @rusins was struggling with the same issue, maybe he has some input.
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Bruh how do your tips not oblate!?
I can literally see them flatten over a cells worth of welds
Idk, something soapy. Window cleaner is good because it leaves no residue. No guarantees though, I just learned recently that Iso or Alc is not a good cleaning agent for most stuffs.
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Iāll just put them in the dishwasher 
I have Windex though, Iāll clean them when I re wrap them
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I find iso good for most stuff. window cleaner is good its basically soap with alcohol. I would definitely still clean with iso after using window cleaner. the stuff just melts anything.
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Its very bad for fatty stuff though, probably due it being a solvent (?). But yeah, Iso after window cleaner is a good idea and wonāt wurt.
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Acetone or if you want toxic power MEK
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Having some minor balancing issues with one of my packs, its a 18s6p. The 5th p-group is showing 30-80mv range of voltage difference from the rest of the 17 packs. (i got it to 10mv difference after 2 days of balancing)
definitely before i learned to be more gentle on the pressure i was applying as i would get into the zone of welding and probably apply a bit more pressure than necessary. I did inspect all welds thoroughly and everything looked good.
I cant really get proper rides to be able to discharge it enough for me to see a pattern/voltage difference - getting worried as every time i check the difference grows. Last night was 30mv, and this afternoon it is now at 35mv (this was after a 20 minute ride - 10mv to now a 35mv difference)
IF this p-group continues to be a problem do i just add more welds to the cells on the existing nickel? or rip it off and do it again? or do i just replace the 6 cells entirely?