Fusing / Resistance Welder

Selection criteria

Closed-loop control of current, force and time; joint monitoring.

Supply chain

Dongguan and Shenzhen motor-line builders integrate fusing and resistance welders into rotor and stator lines, and a Guangzhou resistance-welding maker supplies stand-alone welders. Look for closed-loop control of current, force and displacement and per-joint monitoring.

Buyer FAQ

Fusing (hot staking) or conventional resistance welding for enamelled wire?

Fusing passes current through a hook or tang terminal and electrode, so heat and force vaporise the enamel and form the joint without stripping. Conventional resistance welding passes current through the parts themselves and normally needs bare wire or a pre-stripped joint. For commutator hooks and terminal tangs with enamelled wire, specify a fusing welder with force and displacement control.

What joint acceptance checks should I require?

Require pull tests for each joint type with a minimum force tied to the wire's breaking load (often at least 80 %), plus cross-sections showing no residual enamel, cracks or cut wire strands at the interface. On the machine, ask for per-joint monitoring of current, energy and final displacement (hook collapse), with automatic rejection outside the window.

How do I manage electrode wear?

Fusing electrodes, usually tungsten or molybdenum alloys, oxidise and wear, which shifts heat input and joint quality. Set dressing and replacement intervals by joint count, then confirm them with the displacement and energy trend from joint monitoring. Keep spare electrodes and holders on site, because imported electrodes can take weeks to arrive.

Where it is used