This pack was not made for ESK8 but specifically for RC airplanes 90mm jets configured as an 8S2P pack using EVE 50PL cells.
I’m using an AWithZ P120D welder, but the same results can be achieved with other AWithZ models it doesn’t have to be this one. I’ll be testing the same technique with the P90C, 60, and P30C models as well. The copper brazing material is from my store.
The settings used are: only 30% power, gear 300, pre-heat 0.10–0.15, 2ms pulse, and double pulse mode.
As you can see, this is 0.3mm pure copper welded directly to the battery cell no nickel involved. I achieved a consistently strong weld. I do not recommend this technique for thinner copper like 0.1mm or 0.15mm, as they are too thin and won’t hold firmly in place.
The Idea is the same concept can be used for your packs. I am not sure what i the max current you need but with 0.3mm copper x 15 like this one is you can easy produce over 200A.
I love the idea of minimizing resistance, heating, and voltage drop where ever possible.
I’ve been wondering if the copper welding flux itself, the tin and nickel powder within. make the weld itself fatter/wider and have less resistance.
I’ve read on this forum each weld is considered good for 5 amps. With these new monster tabless cells, capable of 50+ amps continuous, seems copper and more than 3 pair of spot welds will become more desirable on those builds capable of such power.
I’d love to be able to weld 0.3mm copper, even though I could ’ get away with’ far less.
I found the AwithZ P20B 14.6kW spot welder could weld 0.2mm copper with 0.1mm nickel plated steel sandwich, at near full power.
I’d like to not have to use full power.
I found your video about the small, low power Fnisiri spot welder which had no chance of welding 0.2mm pure nickel without the copper welding flux/brazing paste, but then made solid welds with it.
I need to get me some of that product, as I want to build the lowest resistance 10s1P Eve 40PL on the planet.
Looks like it is effective not just for copper to copper spot welding, or copper to nickel welding , but works for nickel to nickel too.
Have you had a chance to test welding that 0.5 and 0.6mm copper?
