How to weld aluminum wire

How best to connect aluminum and copper cable: methods

• Types of cable connections
• What is the best way to connect aluminum cable cores?

How best to connect an aluminum cable: methods

When connecting wires, you need to understand how to do it correctly. Otherwise, the wires may quickly burn out or there will be poor contact, which will lead to the electrical wiring starting to get very hot.

This is especially true for connecting aluminum wires, which cannot be soldered with tin and rosin (mmasvarka.ru). And, of course, you probably know that twisting copper and aluminum wires is not recommended.

Firstly, such a connection will oxidize, which will lead to loss of contact, and secondly, it will become very hot, which can lead to the wire burning out.

Types of cable connections

You can connect aluminum wires to each other in different ways, namely:

• Twisting method. However, this method of connecting aluminum wires has one significant drawback. Aluminum wire is very sensitive to bends, etc. Therefore, it can break in places where it is twisted;
• For bolt and nuts. A more reliable method of connecting aluminum wires than the one described above. To do this, take a bolt and several nuts with washers, between which one and the other end of the wires being connected is clamped. In this case, the connection is quite reliable and durable. Its only disadvantage is that it is bulky, and often open, without any insulation;
• Pads. Universal devices for connecting wires, and those can be made of dissimilar metals;
• By means of a sleeve. You can connect aluminum wires using a small tube for this purpose, which is crimped after two or more wires have been laid in it. Before this, it is recommended to twist the aluminum wires together and then crimp them using a sleeve.

Let's take a closer look at how exactly aluminum cables are connected using all of the above methods.

What is the best way to connect aluminum cable cores?

Twisting aluminum wires - with proper winding, this connection method will last at least 50 years. Twisting of wires can be different, for example, as in the pictures. The second connection method is certainly much better and more reliable.

Bolted connection - take a long bolt and wrap one end of an aluminum wire around it, closer to the head. Then a washer is put on the bolt, and the end of the other wire is wound behind it. After this, everything is tightened with one or two washers. Bolts, washers and nuts are best used to connect wires made of dissimilar metals, such as aluminum and copper.

Terminals and blocks are an equally popular way to connect aluminum wires. This method is fast and reliable, as well as the ability to connect copper and aluminum wires. Today there is a wide variety of terminal blocks, for example, Wago, and simpler ones in design.

Sleeve connection - with this method, two wires are twisted together and then crimped using a cable sleeve. For greater reliability, the sleeve is crimped not with pliers, but with press tongs specially designed for this purpose.

To make a sleeve to connect two wires, you can use a copper tube to connect the air conditioner. The sleeve must have a length of at least 5-7 cm, and its diameter depends on what cross-section of the cable will need to be connected (crimped).

Source: https://mmasvarka.ru/kak-luchshe-soedinit-alyuminievyj-kabel.html

We perform welding of strands of copper wires with our own hands

In order to connect two wires, several techniques are used. This can be twisting, soldering or welding of various wires. The last technique is one of the most successful and frequently used. It helps to achieve long service life of electrical wiring.

It is mainly made from a copper composition rather than aluminum, which is not suitable for these purposes. Welding occurs using direct and alternating current, at a voltage of 12-36 V. Directly for the process, we recommend using an inverter welding machine.

Copper wire welding technology

There is one technique that always leads the welder to the best result. As mentioned earlier, the best device for welding is an inverter. Then they take hold of the wire. It is freed from insulation and excess shell and twisted. When cutting wires, the ends should remain the same length and at the same level, and the twist should be at least 50 mm in length.

Next, a heat repellent copper clamp is installed and the welding machine is connected. The charcoal pencil (or rather its end) is brought closer to the finished twist. When welding, the pencil must be clamped in the holder.

Welding of strands is considered complete once a small molten ball of copper has formed. In order for the insulation to remain intact, you must not overdo it, but devote no more than 1-2 seconds to each twist. When welding of copper wires is stopped, ordinary electrical tape or a similar version is used to insulate the frozen part.

Step by step process

Let's describe the whole process step by step:

1. Remove the insulation on the wires;
2. We make twists;
3. Add mass;
4. Turn on the welding inverter;
5. We bring the electrode to the twist until an arc forms;
6. Contact duration is 1-2 seconds;
7. We proceed to the next twist (if there is one), after the finished one has cooled;
8. We insulate using heat-shrinkable tubing or electrical tape.

Important! Welding wires with your own hands, especially copper wires, requires special experience and knowledge. You will have to work at a temperature of 1080°C, at which copper melts. Therefore, it is worth practicing with simpler examples.

The device should be selected with the ability to adjust the current, the strength of which should be 30-90 amperes. The electrode used is carbon containing copper.

Features of welding aluminum wire

Welding of aluminum wires, mainly found in large industries. For the welding process, use argon or a conventional welding machine. To avoid burning the wire, welding is performed at reduced power.

Some difficulties may arise in the form of an oxide film; the rate of its formation is very high. As a result, it remains on the molten metal. To avoid this, a gas shielding medium and aluminum cable flux are used.

Welding aluminum wire step by step

Let's look at welding aluminum wire step by step:

1. First, remove the insulation and all excess materials;
2. Next, the ends of the workpieces are treated with flux. This will improve the final quality;
3. Turn on the device and set the correct operating mode;
4. We start welding;
5. Then the excess parts that appear as a result of the work are removed;
6. We re-insulate the wire.

To ensure a successful welding, we strongly recommend that you adhere to safety precautions. You need to have fire-resistant clothing, a welding mask and special gloves with you. If gas is used, the cylinders are removed 5 meters or more from the fire. Check all equipment and assess indoor humidity to avoid electric shock.

Welding in a junction box

First, you should get acquainted with the box and appreciate its full significance. This is the most important part of all electrical wiring running throughout an apartment or house. Take this very seriously.

Directly for the soldering process you will need a welding machine. We can recommend one of the most attractive models for such purposes. This is the Patriot Max Welder DC-200 C. It has a silent level of operation, high safety, which is important if there is a lack of experience, and precise operation.

Its weight is 4.5 kg, so there are no problems with transportation. It is powered by a 220 V network, the current floats in the range of 10-190 A. The price is at an acceptable level for everyone, from 8,000 to 10,000 rubles.

This does not mean that you only need to choose this one; there are other devices that are just as suitable for this type of welding.

Welding of copper wires in the junction box begins with ensuring all safety measures. We set the device to a power of about 1 kW. Carbon and graphite electrodes are used. You will also need flux. A mask or special glasses must be used.

To remove insulation and twists of copper wires, you need a knife and a clamp in the form of pliers. Always have electrical tape, nuts and screws on hand. The wire strands are stripped to about 4-5 cm, then twisted around each other 7 times. Let's start welding.

If you are not confident in your abilities, practice on similar types of metal and twists. When everything works out, start. We have already talked about the procedure for welding copper wires earlier.

Thermite welding

Thermite welding of wires is perhaps the most popular method for connecting two current conductors. For the process itself, a special thermite mixture is used. To obtain the correct result, you need to adhere to all rules and recommendations to the nearest millimeter.

This technology is just beginning to gain popularity. It is increasingly used in a variety of areas of production. To carry out high-quality work, the welder must have special knowledge of chemistry at a high level.

Welding wire selection

This cable serves to supply current to the place where the parts are connected. Since the process is the most important, welding wires have high requirements, we list the main ones:

1. The insulation must be heavy-duty and withstand many twisting procedures;
2. The cross-section of the wire must be resistant to the loads created by the inverter;
3. Current-carrying conductors must be in a polymer braid;
4. The wire insulation base must be made of hose rubber;
5. The wire must be resistant to mechanical damage and also not weak to chemicals and aggressive environments.

What are wires for hardware welding made of?

• base winding made of polyethylene terephthalate;
• current-conducting conductor made of copper;
• rubber insulation;
• additional layer of winding;
• main insulation made of rubber.

When talking about lengthening the wire, you can sometimes hear that the quality of the seam may deteriorate. But direct evidence of such a feature has not yet been identified.

Source: https://electrod.biz/varim/svarka-skrutok-mednyih-provodov.html

Connection of aluminum wires

In accordance with the PUE, only three methods of connecting conductors can be used. These include welding, crimping and clamping in terminals. It has long been known that welding shows the best characteristics in all respects (reliability, durability, simplicity). Plus, this method is also quite fast and cheap.

Welding copper wires does not raise any questions. But what about aluminum? Indeed, despite the fact that, in accordance with the requirements of the 7th edition of the PUE, aluminum wires were prohibited for use for electrical wiring, they are still used quite actively to this day. There is only one solution: connecting aluminum wires is possible exclusively by welding.

Why is aluminum welding the best option?

The physical and chemical properties of aluminum make it possible to use only welding for its connection. This is due to a number of reasons.

Reason one: aluminum quickly oxidizes in air, resulting in the formation of a strong oxide film. This film has such high electrical resistance that aluminum is often used as a dielectric when used in low-voltage devices.

Reason two: in the case of using spring or screw connections, the oxide film is destroyed during broaching. At the same time, the contact resistance is still increased - this leads to heating and the ensuing consequences.

To combat this film during the welding process, oscillating devices are used that operate in an inert gas atmosphere. They are ways to break through the oxide film using high-voltage electrical pulses. But these devices are very expensive and bulky.

The best solution is to use a special flux for welding aluminum, which dissolves the oxide film. In this case, the composition of the flux must be optimal so that it simultaneously dissolves aluminum oxide, but at the same time gives a minimal reaction with the metal itself, without releasing harmful compounds that lead to corrosion of surrounding objects.

Using flux to weld aluminum is very simple. It is a white powder that is dissolved to a creamy consistency with water and applied to the end of the twist using a brush or dip.

The process of welding aluminum wires is no different from welding copper wires. The carbon electrode is brought for a couple of seconds from below to the end of the twist. It is important that the surface of the electrode is cleaned of slag and caked scale. Thanks to the flux, the electrode does not stick, since the oxide film dissolves, and the access of oxygen is excluded at the moment of drop formation.

After welding aluminum wires, it is better to wash the ends of the welded strands with a solvent, and then coat them with one of the many options for quick-drying varnishes, followed by insulation.

An important point when connecting aluminum wires by welding

Due to the fact that aluminum has a lower melting point compared to copper, splashing begins at the point where the drop forms. Due to this feature, it is necessary to use a low arc voltage, that is, the voltage on the electrodes should be less than 20V. That is why the TS 700-2 twist welding machine is ideal for welding aluminum wires, as well as copper wires, because the voltage here is only 18V.

Thus, nothing new has been invented in the 21st century for connecting aluminum wires. Everything is also simple and familiar: welding and flux for aluminum. It’s just that the work has become much more convenient, thanks to a specially designed transformer for welding wires TC 700-2, which even a beginner can handle, and a more efficient flux that allows you to weld aluminum without much difficulty.

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Source: https://elektroprizma.ru/articles/article4/

How to connect aluminum and aluminum wire together correctly?

When you need to connect 2 different sections of wire with each other, it is necessary, in addition to high-quality contact, to obtain sufficient strength of the section where these wires are connected to each other.

If we take into account the regulatory documents that are in force in our country, then it is permissible to connect aluminum wires to each other using various methods:

1. Welding.
2. Crimping.
3. Soldering.
4. Connection using terminals.

Despite the fact that all these connection methods specified in the regulatory documents are presented as universal, not all of them will be suitable when working with aluminum wires.

First of all, this is due to the characteristics of a material such as aluminum, in particular, its technical characteristics. As you know from a school chemistry course, there is always an oxide film on the surface of aluminum, formed as a result of direct contact with atmospheric oxygen.

It is not capable of conducting electric current through itself. In addition, the oxide film has a fairly high melting point - around 2000 degrees. This figure is significantly higher than the melting point of aluminum itself.

If you remove this film mechanically, it will appear again very quickly. It is worth noting that the presence of this film when soldering aluminum greatly interferes with the process of connecting the aluminum core to the solder. Also, it can cause difficulties when welding wires, because due to its presence various inclusions arise, due to which the quality of contact is greatly reduced.

Additional characteristics of a material such as aluminum include increased fragility and fluidity. In this regard, when connecting aluminum wires, care should be taken in advance to ensure that they are located so that the possibility of mechanical impact on this area is completely excluded.

It is worth noting that when connecting wires using a standard bolt clamp, it will have to be tightened periodically, since the metal will gradually flow out from under the bolt. As a result, the connection will become weaker.

Twist

Aluminum wires are often connected to each other using twisting. This is the simplest, but also the most dangerous method of connecting wires to each other.

The sequence of actions when using this technology will be as follows:

1. First , remove the insulation from the wires approximately 4-5 cm on each side. It is most convenient to use a special tool designed specifically for this purpose.
2. Now the contacts should be degreased. To do this, you will have to wipe them with a cloth pre-moistened in acetone.
3. Sandpaper is used to remove the oxide film from the surface of the metal, that is, to clean it until a metallic shine is obtained.
4. The wires are crossed with each other , after which one of the wires is wound as tightly as possible onto the other using pliers.
5. The second wire is wound onto the first in the same way.
6. The twist should now be insulated using insulating tape. Professional electricians also recommend using a special heat-shrinkable tube or cambric. With its help, you can qualitatively protect the exposed area from the negative effects of the external environment.

In principle, the technology is quite simple. You just need to remember that the wires need to be exposed at least 4-5 cm, and the twisting should not be done manually, but only with the help of pliers, so that the wires fit as closely as possible to each other.

If this is not done, the result will be loose contact, which can cause the area to become very hot. In turn, this effect causes a short circuit, and in some cases even a fire.

Threaded connection

This type of connection can be very reliable if done correctly. It is worth noting that aluminum has the greatest linear expansion, and therefore a gap appears between the connected wires over time, worsening their contact with each other. To prevent short circuits, you need to tighten these screws from time to time.

To get rid of this need, special washers with cuts or groovers are installed. They select the resulting gaps and increase the reliability of the connection several times.

The wires will need to be wound around the screw so that the area of ​​its contact with the contact pad is much larger. Professional electricians often do this: they flatten this ring on an anvil to increase the contact area.

The technology for making high-quality threaded connections of wires begins with removing the insulation from them to a distance equal to 4 screw diameters. The cleaned areas are degreased.

Then you need to bend their tips so that rings are formed.

The elements are put on the screw in the following sequence:

1. Spring washer.
2. Standard washer.
3. Ring of the first wire.
4. Another standard washer.
5. Ring of the second wire.
6. Screw.

This entire system is tightened until the spring washer is in a straightened state. In principle, if both wires are made of aluminum, then there is no need to place a standard washer between them.

We use terminal blocks

If aluminum wires have a low current load, they can be connected to each other using terminal blocks. Despite the fact that the appearance of such products may vary greatly, the principle of their operation is the same.

The body of the pads is made of plastic or carbolite. It contains tubes with thick walls made of brass. There are threaded holes on the sides. The wires to be connected are inserted into opposite ends and secured with screws. It should be noted that you can insert as many wires into one brass tube as will fit there.

This is not a very reliable connection compared to soldering, but installation work takes several times less time. In addition to connecting conductors made of the same material, it is permissible to use different wires in terminal blocks.

Permanent connection

If you do not plan to disassemble the wire connection in the future, you can use the so-called one-piece methods. These methods are among the most reliable. It is advisable to use them, first of all, in hard-to-reach places.

One of the easiest methods of permanent connections is crimping. To do this, take an aluminum tube of suitable diameter, twist the wires together, insert them into this tube and clamp them with press pliers. It is best here that the conductors fit as tightly as possible.

Only in this case will the connection be the most durable. It is worth noting: if the wires fit into the tube quite tightly, then you don’t even have to twist them together. At the last stage, the connection is isolated.

Today on sale you can find special tips for making this connection, which already have an insulating cap. It shrinks together with the tip and wraps around the wires, blocking any access to them.

To obtain a high-quality permanent connection, you need to have special pliers that will not bite, but only squeeze. If they are not available, then standard pliers will do just fine.

Soldering and welding

Soldering wires allows you to get a fairly high-quality and permanent connection. However, when connecting aluminum wires, you should be aware of the presence of an oxide film on them, due to which the solder will not adhere very well.

To prevent such a defect from occurring, you need to follow a certain sequence of actions:

1. The connected sections of wires are treated with a special flux, which removes the oxide film from the surface.
2. The solder is processed as carefully as possible so that it has the largest area of ​​contact with the wires.
3. When the connection area has cooled , it is advisable to treat it with sandpaper to remove sharp edges that could damage the insulating layer.
4. Wires must be insulated.

Soldering requires certain skills.

It should be said that this method has several negative aspects:

1. He has to be isolated.
2. The method itself is quite complicated , especially if you have to solder wires under the ceiling while standing on a stepladder.
3. If an error was made during the work , then correcting it will be quite problematic.
4. A lot of time is spent on work.

Welding is somewhat reminiscent of soldering wires, but it is much faster. In order to obtain a high-quality connection, the electrode is brought to the connection area for only 1-2 seconds. Both ends of the wire are pre-treated with flux to remove the oxide film.

If you have no experience in this area, then you should initially practice on twists prepared in advance, but not connected to the system.

After completing the welding process, the twists are treated with a special solvent and varnished.

The result is a high-quality connection that can last for a long period of time, since this method helps prevent overheating. Accordingly, such an area will need to be isolated.

Alternative options

flat spring clamp

The wires can be connected to each other using a rivet. In principle, this technology is similar to screw technology, only here a rivet is used instead of a screw. The end result is a permanent connection.

This connection is made quite simply: both conductors are put on the rivet through a spring washer, then it is inserted into the rivet gun and the handles are pulled together until a click is heard.

There is also a special flat spring clamp. Such products are disposable and reusable, when the wire can be either inserted or removed. However, it should be remembered that such clamps are made of plastic, so it is not advisable to use them for currents exceeding 10 A.

Working with them is very simple: the wires are stripped and inserted into the clamp until they click. It is impossible to pull them out from there without using a special lever. It is also advisable to insulate this section of the wire.

Connection Features

Aluminum wires are best placed in special junction boxes, to which they should be approached in corrugated sleeves. This is especially important when the installation is carried out outdoors or in the case of wiring in a damp room such as a bathroom.

In general, when connecting aluminum wires that will function outdoors, care must be taken to ensure that moisture does not approach the connection areas.

Otherwise, short circuit will not be avoided. In this case, it is very convenient to use the technology of welding wires, since the subsequent use of a special varnish eliminates the impact of water on the joint, and the insulating layer will additionally protect against electric shock.

Blitz tips

1. Professional electricians do not recommend connecting aluminum and copper wires together. This is due to many reasons, the most important of which is the different resistance of metals. In addition, when interacting with each other, copper and aluminum oxidize very quickly, which causes heating of the wires and significantly worsens the contact. In addition, their rigidity is different, which significantly complicates the work.
2. You can, if necessary, combine certain methods of connecting wires. In particular, twisting goes well with soldering or welding. The result is a very reliable and permanent contact that will last for a long time.

Source: https://housetronic.ru/electro/alyuminievyj-provod-soedinenie.html

How to connect aluminum wires to copper wires correctly?

Depending on the type of connection you choose, you will need different materials and tools.

For mechanical connections:

• pliers;
• knife or device for removing insulation;
• PPE caps;
• terminal blocks;
• self-clamping terminals;
• sleeves;
• screw terminals;

When crimping, you will need presses (hydraulic, mechanical, manual of various types, press pliers, etc.).

For welding you will need the following:

• argon-arc welding machine;
• oscillator;
• rubber boots;
• welding mask;
• burner;

For soldering;

• knife or device for removing insulation;
• soldering iron (for small sections of aluminum wires – 60-100 W; for sections larger than 2 mm – 100-200 W);
• solder (POS40, POS60 solders are ideal for home use);
• steel brush;
• sandpaper;

The choice of fluxes deserves special attention, since the better the flux, the easier it will be to solder aluminum. Today, despite the large selection of fluxes, the most preferred ones for soldering aluminum at home are FIM, F-64, FTBf.

Connection methods

The need to connect aluminum products with copper, aluminum or aluminium-copper especially often arises in Soviet-built apartments - this occurs due to the failure of individual sections of aluminum electrical wiring, or due to its complete replacement.

Few people know that the joints must be as strong as possible to prevent heating. If the work done is done poorly, the resistance will increase, causing them to heat up, which will result in a short circuit.

The following methods exist:

1. Soldering.
2. Welding.
3. Mechanical connections:
   • twist;
   • use of terminal blocks;
   • use of contact clamps (self-clamping terminals);
   • connection using bolts;
   • crimping method (crimping);
   • spring devices;

Each of the listed methods has characteristic features.

Twist

It is considered the most short-lived method , especially when the connection occurs with cables made of other metals. However, there are also rules for twisting, compliance with which will significantly improve the quality of work, increase service life and safety.

types of twists

Types of twists:

1. Bandage twist. Bandage twisting is used to connect cables of large diameters. To strengthen the bandage twist, soldering is used - exclusively after tinning the copper wire.
2. Twisting with a groove. The strongest twist.
3. Simple twist . Simple twisting is used exclusively in domestic conditions; this method is most often used to connect current-carrying conductors in junction boxes.

It is not recommended to use twisting for conductors with a cross section exceeding 10 mm2. (for comparison, the average thickness in distribution boxes is 1.5-2 mm2).

Particular care must be taken when connecting multi-core wires (cables):

1. The twisted areas must be cleaned.
2. To strengthen the contacts obtained, it is recommended to use PPE caps.

Welding

Welding aluminum wires at home is a labor-intensive process that requires experience and special knowledge. The main feature is that the seams resulting from welding must form an exclusively integral whole with the original product - only if this condition is met, the current can flow unhindered.

Obtaining a positive result is complicated by the fact that when welding in air, the aluminum surface is covered with a refractory oxide film, so argon-arc welding or fluxes are used.

Welding has a number of specific features:

1. The additive must be applied in short reciprocating movements.
2. The filler wire together with a special electrode must be at an angle of 90° during welding.
3. It is necessary to adhere to one selected arc length (most often 1.5-2.5 mm).
4. The electrode should be 1-1.5 mm away from the burner tip.
5. Welding must be done exclusively from right to left.

Spike

The safest method is soldering - with certain skills you can perform soldering at home:

1. Before soldering, the ends of the wires must be tinned: the part that will be connected is thickly coated with rosin and placed on a grinding surface (wheel or sandpaper).
2. Next, the wire is pressed to the surface with a soldering iron, constantly adding rosin until the required thickness of the wire is achieved.
3. After which the soldering is carried out in the usual way.
4. The most important thing in the soldering process is to prevent the aluminum surface from coming into contact with oxygen - otherwise, a heat-resistant oxide film will form. To do this, the cable to be stripped is generously lubricated, or filled with flux, and in some cases, heated.
5. In the case of soldering wires with a cross-section of up to 4 mm2 , they can be cleaned directly in the solution.
6. If the cross-section of the aluminum wire is 4-10 mm2, it is necessary to remove the insulation, clean it to a shine and twist it.
7. When soft solders are used , AF-44 flux is optimal.
8. The resulting connection should be cleaned of flux residue, wiped with gasoline, coated with moisture-resistant varnish, then with electrical tape, then with varnish again.

Crimping (crimping method using sleeves)

For cases when it is necessary to connect a multi-core cable, or more than 2 single-core wires into one connector, it is best to use crimp sleeves:

1. into such a sleeve .
2. After which the sleeve is compressed using a press or special pliers, a reliable, permanent contact.

This method is most widespread when connecting powerful consumers.

Instead of sleeves, NKI tips are widely used, at one end of which there is a small crimp sleeve - cable cores are inserted into it. At the other end there is a slip ring, thanks to which you can get a high-quality connection with screw terminal blocks.

Using Terminal Terminals

The easiest way to combine aluminum cables into a single current-carrying core is to use contact clamps.

Their types:

• polyethylene clips;
• self-clamping terminals (terminal blocks);
• screw;
• spring (PPE caps);

Advantages of contact clamps:

1. They do not require additional insulation ; to connect, it is enough to strip the aluminum cables, assemble them into a bundle, and then screw the clamp onto the bundle until it stops (insert it into the terminal, or clamp it with a screw, etc.);
2. The resulting contacts have much greater mechanical strength than when twisted;
3. The resulting contacts do not heat up, which minimizes the possibility of short circuits and fires.

Screw connection

Screw (bolt) connection is the most common contact connection of aluminum wires and cables to electrical appliances, instruments, and machines. However, the properties of this metal to spread under excess pressure, along with the difference in coefficient. Thermal expansion of aluminum and the metal of the screw (bolt) can lead to mixing of the screw contact of the wire.

Subsequently, the ring gradually creeps out from under flat washers, most often used for screw (bolt) contacts.

To prevent the described violation (which can lead to short circuits), cable clamps must have the following devices:

1. Limiting the unwinding of the cable ring (limiting star washers).
2. Preventing contact pressure from weakening after yielding (standard spring washers).

Spring connection (PPE caps)

These are caps made of non-flammable plastic, with metal springs located inside. After screwing the PPE onto the wires (twisting), the springs move apart, compressing the cable cores and ensuring tight and reliable contact, and also removes the layer of oxides from the wires.

At the same time, plastic serves as electrical insulating, fire and mechanical protection for the entire connection. For high-quality contact, the size of the PPE caps must be selected correctly - they must be screwed onto the cables with force.

Safety precautions

1. Connecting wires, you must be careful and strictly follow the operating instructions, which prohibit simple twisting (twisting in a spiral) of wire made of aluminum and any other metal (copper, aluminum-copper, aluminum).

   The reason is that when aluminum oxidizes, it releases galvanic vapor, which will sooner or later break the contact, and sparks that occur when high-power currents pass through such contacts often cause a fire.

2. The most dangerousis aluminum welding – To avoid trouble, be sure to use rubber boots and a welding helmet.

3. in the room where welding is carried out to prevent fire.
4. Even wooden floors are recommended to be covered with iron sheets.

Adviсe

1. When using a bolted connection, it is necessary to remember about the fluidity of aluminum - the clamping bolt must be periodically tightened so that the aluminum does not leak out over time. At the same time, the mechanical pressure on the cable without tension should not exceed 150 kg/cm2. When the tip is clad with copper, the pressure should not exceed 100kg/cm2. When heating live wires, the maximum pressure is no more than 200 kg/cm2.

   If these values ​​are exceeded, the aluminum cable will “leak” under voltage.

2. If you have no other choiceIn addition to using simple twisting, you must remember that the contact will be more reliable when using certified PPE caps. Remember that any cable contacts covered only with electrical tape are not recommended.

3. For quick and high-quality soldering of aluminum cables, it is necessary to replace rosin with high-quality mineral oil (for sewing machines) or gun oil.
4. When choosing self-clamping terminals , we recommend reading the markings, which display the number and cross-sectional area of ​​the cable for which the device is designed.
5. Any mechanical connection of an aluminum wire with a copper wire is possible only when the latter is coated with tin-lead solder.

Source: https://slarkenergy.ru/provodka/cable/kak-soedinit-alyuminievye.html

Welding copper and aluminum wires

The most important and responsible component of the installation and assembly of power supply systems is the connection of wires in distribution boxes.

High-quality and reliable contacts at the points of connection of electrical network elements, made in accordance with the requirements of the Electrical Installation Rules (PUE), are a guarantee of operability, durability, and most importantly, electrical and fire safety. In this article we will tell you how to weld wires in a junction box with your own hands.

It is important to know

The simplest and fastest way to solve the issue of how to connect wires is considered to be twisting, but at the same time twisted wires represent a very low degree of contact reliability. Due to low reliability, it is not acceptable according to Chapter 2.1. PUE clause 2.1.21 shows the following acceptable connection methods: screw or bolt clamps (terminal blocks of different types), checking and soldering.

Terminal blocks and crimping devices increase the reliability of installation, but are several orders of magnitude inferior to such a connection method as welding. When preparing for electrical installation, weighing all the pros and cons, you should definitely cast aside doubts and give preference to this method.

People who are not knowledgeable about electrical installation issues have the opinion that this connection method is an unacceptably advanced technological process that requires the highest qualifications of the performer and the use of highly complex equipment. In fact, everything is very simple and accessible. Welding wires with your own hands is entirely within the capabilities of a person who has basic skills in handling an electric welding machine at home.

The question is very relevant for our time, since inverter welding machines became available for mass purchase. An inverter welder is very convenient and practical, it consumes little electricity and can be operated from the mains, and the cost of low-power models ranges from 50-100 dollars.

As a device, you can use a homemade device made on the basis of a step-down transformer. For a person who has knowledge and skills in the field of electrical engineering, the question of how to make a welding machine with your own hands is not difficult.

Electrical installation companies specializing in welding use special welding machines in their work.

What you need to prepare

In addition to the apparatus for welding work, you should prepare and have available all the necessary equipment, materials and tools. The wires are welded using carbon (graphite) electrodes.

As such electrodes, you can use either an industrial version (such as the EG brand) or a brush from an electric motor, a piece of a shoe from a trolleybus, graphite cores from batteries type 3336 (3R12) or modern salt ones. For the manufacture of conductor products, copper and much less often aluminum are used.

For information, according to the latest PUE requirements, the use of aluminum conductors with a cross-section of less than 16 mm2 is prohibited.

Depending on what will have to be welded - aluminum or copper, the composition of the flux is selected, designed to chemically dissolve the oxide film formed during welding. When welding aluminum wires, you need to use flux, copper can be welded without it, you must first clean the conductors in both cases

In the process of preparing the ends of the conductors and as work progresses, you will need a knife, pliers, and electrical insulating materials.

By the way, an alternative option is to connect the wires by soldering. Read our article about how to properly solder wires!

Process Features

Before you start welding electrical wires, you should set up the machine. Considering that the conductors being welded can be of different cross-sections, the current at the output of the welding machine must be selected experimentally so as not to cause overheating of the connected conductors or sticking of the electrode at the connection point. The ends of the conductors must be stripped of insulation (bare conductors must be 5 cm or more in length) and connected to each other, as is done when twisting.

Having pre-treated the twisted bare ends with flux (in the case of welding aluminum), we clamp them with pliers and attach the mass to them, the electrode is brought to the end of the twist, which should be directed downwards, and held in this position for 0.5 to 2 seconds. Once you are sure that a copper or aluminum ball has formed at the point of contact, stop welding.

After the connection has cooled, remove the flux with sandpaper. Before applying an insulating coating to welded wires, it is recommended to treat this area with a solvent, followed by coating with electrical insulating varnish. However, keep in mind that the ball at the end of the twist should be smooth with a minimum number of pores.

Otherwise, the welding site will burst.

It is strictly forbidden to connect live conductors. Before starting work, using a probe, you need to make sure that it is missing. To protect your eyes, face and hands from burns when working, be sure to use a protective mask and gloves.

Source: https://samelectrik.ru/svarka-mednyx-i-alyuminievyx-provodov.html

How to cook aluminum with an inverter without argon. Connection of aluminum wires

In everyday life, products made of aluminum alloys are used, which occasionally require repair.

Is it possible to weld aluminum at home with an inverter? Yes, with the help of special electrodes, home craftsmen weld cracked or new products.

How to cook aluminum with an inverter without argon

First, special aluminum electrodes for electric arc welding are purchased. In this article, you can get acquainted with melting rods for joining aluminum alloys.

Aluminum welding with an inverter is performed using direct current of reverse polarity (+ on the electrode holder). For a running electrode with a diameter of 3.2 mm, the welding current on the machine is set to 80-100 A.

When connecting aluminum alloys, the holder with the electrode is placed at a right angle (90 degrees). The technology is performed with a short arc.

Please note: aluminum electrodes burn 3 times faster than usual, maintain the correct speed.

Thick metal more than 5 mm needs cutting edges. The V-shaped chamfer is cut with a bevel of 45-60 degrees.

Before welding, the workpieces are heated with a gas burner to 150-200 degrees for drying. And the electrodes are pierced in an oven according to the manufacturer’s instructions.

Without heating the aluminum products and drying the melting rods, the connection will not work.

As the workpiece heats up, you will see water appear on the surface and evaporate.

Further, the products are installed with a technological gap between them of 1-2.5 mm, depending on the thickness of the plates.

The oxide film is removed with a stainless steel brush (the use of abrasive tools is not recommended; abrasive particles will create joint defects).

After preparations, aluminum is welded with an inverter. After each pass, with thick metal, slag is removed with a hammer. Slag welding is not performed. Electrodes for aluminum alloys require cleaning of the tip as the process continues.

Aluminum alloys are divided into difficult and easy to weld. The table will help determine the weldability characteristics.

Welding inverter for aluminum welding

Inverter welding machines for aluminum welding are purchased in different brands and modifications. We looked at the use of electric arc devices. In practice, semi-automatic devices and attachments are also used for connections in a protective gas environment.

This article explains how to learn how to weld aluminum using argon gas.

Connecting wires by welding

How to weld aluminum wires with an inverter? The essence of the technology is simple:

• remove the insulation from the wires;
• make a twist;
• trim the twist (wires at the same level, length more than 30 mm);
• apply flux to remove the oxide film.

For connection, graphite or carbon electrodes and flux are purchased. Flux is a white powder, diluted with water until creamy and applied to the twists with a brush or by immersion. The flux removes the oxide film and prevents the carbon electrode from sticking.

The connection is made without an arc, by simply bringing the electrode to the twist for 1-2 seconds. On the inverter device, the current strength is set to 20 A.

The tip of the electrode must sometimes be cleaned of slag and scale. Before important work, it is better to practice on blanks.

After work, wipe the aluminum connections with solvent, apply varnish and insulate.

Source: http://stroymaster-base.ru/instrumenty-i-materialy/kak-varit-alyuminiy-invertorom-bez-argona-soedinenie-alyuminievyh-provodov.html

Methods for soldering aluminum wires

Despite the fact that in modern construction, during electrical work, aluminum cables are increasingly being replaced by copper cables, aluminum remains an indispensable material in the manufacture of large-section wires and cables.

The reasons for this lie on the surface - the electrical resistivity of aluminum is approximately one and a half times greater than that of copper, and the volumetric weight is three times less.

With a large conductor cross-section, when weight is more important than strength, the choice in favor of aluminum is obvious. The cross-sectional area of ​​an aluminum conductor will be one and a half times greater than that of a copper conductor, and at the same time, aluminum will still be two times lighter than copper. Soldering, among other methods, is used to connect wires.

Soldering methods

The problem with using aluminum conductors is their rapid oxidation. The oxide film significantly impedes the passage of electric current during connections. To do this, twisted aluminum wires are soldered.

You can solder aluminum wires in a junction box using a soldering iron or a gas torch. It is more difficult to use a soldering iron due to the inability to accurately heat to the required temperature. And for aluminum, overheating is just as unacceptable as underheating.

Metal has high thermal conductivity, and the insulation over a large area from the soldering point can simply melt.

It is easier to regulate the heating temperature with a gas burner, but it takes a long time to prepare the surface. However, it is the torch that will need to be used if it is necessary to solder any massive parts to each other. In any case, when soldering aluminum wires, they need to be prepared.

Preliminary processing

The difficulty with soldering is that aluminum itself is a very low-melting material (660 ℃) and if heated carelessly it can melt.

Another factor that makes soldering aluminum wires difficult is rapid oxidation in air.

The oxide film on the surface of the material reliably protects aluminum from the effects of all kinds of external factors, but it also prevents the adhesion of solder to the material and must be removed.

It is almost impossible to mechanically remove the oxide film under normal conditions. The material is instantly oxidized and covered with a new film. You can mechanically remove the oxide film under the oil layer.

But before this, the oil must be heated to 200 ℃ in order to remove any active oxygen that may be present there. This method is very inconvenient at home and labor-intensive.

Therefore, the ends of aluminum conductors must be tinned before soldering. Using rosin or most other fluxes will not work due to the high chemical resistance of the oxide film. It does not dissolve even with organic acids.

To tin the wires, you must use both a special flux and a mechanical method.

Of course, this must be done before the wires are twisted, otherwise it will not be possible to mechanically clean the entire surface of the wire. Only the tinned ends can be twisted together and soldered.

Working with a soldering iron

In order to solder aluminum with a soldering iron, there are several methods, the essence of which is to clean immediately under the flux layer in direct contact with the molten solder.

The first method is that aluminum conductors, before soldering, are cleaned with a hot tinned soldering iron using a mixture of rosin and steel filings.

Sawdust has an abrasive effect, rosin removes all impurities and immediately the cleaned areas are covered with solder, which should be on the soldering iron tip.

The second method involves stripping the aluminum wire on medium-grit sandpaper directly under the influence of a hot soldering iron with solder and flux.

Gas burner

Processing with a gas burner is carried out when the parts are in the position relative to each other in which they will be used. The processing smoothly transitions into the soldering process itself.

This happens as follows:

• the burner heats the surfaces of aluminum parts;
• upon reaching the temperature at which the metal is reduced from the oxide, the film is mechanically peeled off;
• under the influence of a flame, the parts are coated with flux, and solder is introduced into the soldering area.

If the parts are thick, then their edges must be cut at an angle of 45°. Typically, heating occurs to the melting point of tin, when the solder spreads and fills the twist groove.

Differences in technology when using flux

Thanks to the achievements of modern science and technology, flux compositions for aluminum have been obtained that actively dissolve the oxide film and protect the material from further oxidation.

Examples of such drugs are formulations labeled F-59A and F-61A. The letter A means that these compounds are intended for soldering aluminum.

When using these fluxes, soldering aluminum wires is greatly facilitated. It is enough to simply treat the finished twist with flux, without even heating it, and then, after heating it with a soldering iron or torch, apply solder.

It will spread over the entire surface of the wires and adhere well, providing a strong and electrically conductive solder joint.

Features of soldering stranded wires

Stranded wires must be soldered only using a special flux, since their mechanical processing is almost impossible. Soldering technology differs in that each wire must first be well treated with flux.

To do this, the bundle will have to be untwisted and fluffed. After processing, each thin wire conductor is covered with solder and the bundle is twisted. After this, twist the two ends and solder it.

Can it be connected to copper?

Situations often arise when it is necessary to connect an aluminum wire to a copper wire. This is perhaps the only case where soldering cannot be used.

It's all about the aluminum itself. It cannot be soldered to other metals at all due to its physical and chemical properties. When connecting directly to copper, galvanic corrosion will occur between the two active metals and will quickly destroy the connection.

And if they are soldered using solder that is neutral to both materials, then the different coefficients of thermal expansion of the metals will quickly destroy the soldered contact. After all, when current passes through a conductor, it will certainly heat up, and after switching off, it will cool down.

Difficulties in soldering aluminum wires

The main difficulty when soldering aluminum wires, as indicated above, is the presence of an oxide film on the surface of the metal. Fighting it greatly slows down the soldering process.

And if you consider that aluminum wires are now used mainly for laying external power wiring, it becomes obvious that a regular soldering iron and sandpaper will not be enough in this case. Welding is increasingly being used to connect such wires.

Source: https://svaring.com/soldering/praktika/pajka-aljuminievyh-provodov

How to weld copper wires at home

Copper wires are more practical than aluminum wires; they are often used for wiring in private homes and laid when renovating apartments. Several ways of designing cable joints are allowed: they are secured with terminals or soldering.

Crimping or compression of the twist is allowed, but the most reliable connection is formed by molten copper. To weld copper wires on a line or in a distribution box, spot technology is used.

It is necessary to melt the twist to a homogeneous structure so that the resistance in the circuit does not increase. This is done for fire safety.

Features of welding copper wires

Copper melts well and is quickly saturated with hydrogen and oxidizes in the molten state. The melting point of copper alloys is no more than 1000°C. To protect the metal when welding copper parts, argon or carbon dioxide is used, but welding wires in a protective atmosphere is not economically feasible. For welding copper cables, conventional machines are used that generate direct or high-frequency alternating current and voltage from 15 to 30 V.

It is desirable that the operating current be regulated; to twist one core with a cross-section of 1.5 mm2, a current of 70 A is required; to connect three wires, the amperage will need to be increased to 90–100 A. To install copper wiring in a house with the connection of powerful electrical equipment, it is necessary to choose welding machines up to 120 A. If there is no optimal current, the arc will be interrupted and the electrode will begin to stick.

Soldering or welding copper wires - which is better?

The simplest and most effective soldering method is to immerse the contact point in molten solder. For small circuits this method is suitable. But it is not suitable for installing lines made of copper wires. Soldering with tin solders by weight requires skill; beginners cannot cope with such work, and there is a high risk of injury. Connecting wires with your own hands using contact welding is much safer.

Another advantage of welding is that the chemical composition of the wires does not change, and no solder particles get into the alloy. The electrical conductivity of the copper cable at the point of twisting does not change. Welding is faster than soldering; there is no need to pre-tin the contacts or select a soldering iron according to the power of the cable size. There are multi-core cords that cannot be soldered.

Welding has the only drawback: if you do not have the skills, you can damage the integrity of the insulation of the copper wire.

Welding machine

For welding copper wires, any current generator is used: transformer, rectifier, inverter. Resistance welding pliers are connected to car batteries, the two are connected in series, and the contacts are brought out to the electrodes. There is enough power to connect the cable to a 5 mm core. You can’t do a large volume with batteries; you need a welding machine.

Inverter

The advantages of modern inverter devices are obvious:

• they can weld wires of any cross-section;
• they are not afraid of voltage “sagging” in the network, they reduce the risk of electrode sticking and burning of copper strands;
• there are lightweight models that deliver current up to 150–200 A;
• operate from a standard network, no need to connect to three-phase current.

Working with an inverter is easier than working with a transformer. For direct current welding of direct polarity, the plus is connected to the electrode holder, the minus to the copper wire being welded.

Transformer

Bulky old-type devices are difficult to drag from place to place, but transformers are capable of generating current within 400 A. The transformer is suitable for working with direct current of direct or reverse polarity. They are used for welding copper busbars in distribution panels and connecting twisted conductors of large cross-section.

The transformer is connected in the same way as an inverter: “+” to the electrode, “-” to the twist. Transformants have good performance, but during operation they hum a lot, get hot, they are periodically turned off and allowed to cool. When turned on, they “sag” the network, but then the voltage stabilizes. When working with a transformer, this should be taken into account.

Based on a step-down transformer with a power of up to 150 A and voltage from 12 to 38 V, you can make a welding machine yourself from household appliances: you need to wind the number of turns of cable around it. You can calculate their number using tables.

If you include a diode bridge in the electrical circuit, it will stabilize the arc. The holder can be purchased at the store or a trolleybus contactor clamp can be used instead. Clamping conductive pliers are made from pliers - a contact terminal is screwed to one handle.

Be sure to ground the homemade device.

Technology for welding strands of copper wires

The connection consists of melting the welded conductors with an arc when passing current, the clamping device compacts the structure of the diffuse layer. It is worth considering the process of welding strands of copper conductors in more detail. Step-by-step instruction:

1. The ends of the cable to be connected are cleaned and the insulation is removed at a distance of up to 7 cm so that the wiring is not damaged during operation.
2. The cores or threads are folded in parallel, they must be tightly twisted together, the type of twisting does not matter, but when axially joining in the direction of the conductors to each other, it is more difficult to weld the twist.
3. The length of the twist should reach 5 cm, excess fibers are cut off. The wires are placed between the contacts or in a homemade clamping device at a distance of 2–3 cm from the edge.
4. After touching the conductors with the electrode, an electric arc occurs; it is held for no more than 2–3 seconds, depending on the thickness of the conductors.
5. The copper is melted in the clamping device, creating a strong connection.
6. The cooled connected conductors are wrapped with insulating tape or heat-shrinkable film is put on it.

Source: https://svarkaprosto.ru/tehnologii/svarka-mednykh-provodov

Do-it-yourself welding of copper and aluminum wires

The provisions of the PUE recommend welding of wires as one of the most reliable methods of connecting them. The advantages of using this method significantly outweigh the few disadvantages, which makes it popular among home craftsmen and professional electricians.

Pros and cons of welding, its varieties

The advantages of connecting wires by welding are the absence of transition resistance, which is always present in twisted or bolted connections. This is especially true when laying wiring for powerful devices.

The disadvantages are the need to buy or make your own welding machine designed for twisting.

Welding work requires some skills, so the electrician who will weld the strands needs to learn at least the basics of this craft.

When performing electrical installation work in production, various types of welding are used: standard, arc spot, plasma, torsion, electron beam, ultrasonic, or various combinations thereof. For domestic use, electricians most often use a device for spot and arc welding, which operates on carbon or graphite electrodes.

This solution allows you to obtain good quality connections at a minimum cost of the necessary devices and components.

When making a wire welding machine, most attention should be paid to the following characteristics of the device:

• The current strength that the device can produce. Ideally this is a variable value.
• The voltage produced by the device is sufficient to cause an electric arc - usually 12-32 Volts.
• What kind of current does the welder use - alternating or direct? If you have experience in such work, you can use variable, but for beginners it is strongly recommended to start with constant.

Since welding different metals requires different currents and voltages, universal welding machines can necessarily adjust these values.

In addition, when joining different materials, you may need special fluxes that will protect the metal from oxidation or the penetration of gases from the air into it.

Most universal-purpose welding machines are quite bulky and heavy, but for small welding jobs you can find inverter welders for a relatively low price that are ideal for welding wires.

If you are welding copper wires that are used in home wiring, there is no need to use very high current and voltage, so it is possible to use small-sized welding machines that fit into a standard tool case.

The principle of operation of arc welding - device diagram

Since welding requires a large current, the basis of any welding machine is a step-down transformer - a loss in voltage is always accompanied by a gain in current and vice versa.

A standard diode bridge is used to convert alternating current into direct current, and a capacitor is used to smooth out ripples.

A noticeable disadvantage of using a direct current device is that the diodes and capacitor used are rather large and they significantly increase the weight of the welding machine, which is initially made portable.

Experts also recommend installing additional resistance at the input or output of the diode bridge, since diodes “do not like” a short circuit in its pure form.

Many craftsmen manually assemble a welding machine for welding copper wires, which produces an arc from alternating current and use them successfully. Therefore, it is impossible to say unequivocally that it is necessary to use a direct current device - everyone chooses the necessary model according to their skills. If an AC welding machine is manually assembled, then the diode bridge and capacitor are simply thrown out of the circuit.

A necessary skill that you will have to master to use an AC welding machine is to learn “by eye” to determine how long you should hold the ignited arc of the electric discharge so that the end of the twist heats up and fusions.

The most common way to make a negative contact for welding is with old pliers that hold the wires.

For the phase, take a clamp that can hold the graphite rod. The design of the clamp can be very diverse - from a screw connection to the so-called “crocodiles”, both home-made and factory-made. To connect to the welding machine itself, cables with a cross-section of about 10 mm² are used.

Despite the fact that a device assembled in an industrial environment is an order of magnitude more expensive than a homemade one, its price is not exorbitant and allows you to purchase such a welding machine even on a limited budget. The advantages of its use are obvious - it is a precisely calculated design with a current regulator, which allows you to work with different types of metals and the number of wires being welded.

Nuances of the wire welding process

With the necessary skills, welding conductors does not take much time, but in order to obtain a high-quality connection, it is strongly recommended that you first practice on separate pieces of cables. Moreover, this must be done if you are using a twist welding machine that works with alternating current - you need to get used to the power of such a device. The whole process is clearly shown in the following video:

Step by step everything looks like this:

• Stripping wires. A feature of welding is the need to expose the wire cores to a length of 60-80 mm. Less is impossible, since during welding the wire heats up quite strongly and the insulation will melt.
• Twisting wires. It would seem that you can simply fold the wires and weld - a drop will still form at the end, which will connect everything together. The problem with this connection method may be the fragility of the wires - it is not a fact that it will occur, but for some reasons, the droplet resulting from welding with a carbon electrode acquires a spongy structure and is susceptible to fracture. This does not affect conductivity, but if the wires are not twisted, they may break.

• Trimming the twist. The fluffy ends of the veins must be trimmed to get an even cut. Then the arc during welding will evenly heat the entire surface of the twist and the drop will be even.

• Welding. The twist is grabbed with pliers and a graphite electrode is brought to its tip until an electric arc occurs. It must be maintained until the ends of the wires fuse, forming a smooth drop. The next twist is welded after the previous one has cooled.

If the arc does not appear, then the power of the transformer is insufficient or the wires to the electrode holders are too long (their resistance prevents sufficient current from being obtained).

The optimal option for the length of the wires is 2.5-3.5 meters, but in the first case you will have to place the welding machine on a stand for ease of operation.

• Twist insulation. The best option in terms of speed here would be to use heat-shrinkable casings, but to warm them up you will additionally need a hair dryer or a good lighter. There is also no hindrance to using ordinary electrical tape - except that it will take a little longer.
• Welding copper and aluminum wires. In general, it is performed in exactly the same way as a regular one - the only difference is in the preparation of the wires. The copper core remains straight, and the aluminum core is wrapped around it. Then flux is applied to the aluminum, which, when heated, removes the oxide film from this metal, and welding can begin.

But if you follow the instructions of the PUE, then in domestic conditions you are unlikely to have to work with aluminum wires, since the use of such cables with a cross-section of less than 16 mm² is prohibited for laying electrical wiring.

Welding wires with an inverter

The use of such a device is most preferable, since welding copper and aluminum wires with an inverter is much easier than with homemade welding machines. This is a universal device, the current in which is adjustable in the range of up to 160 Amperes. In addition to the fact that it can weld twists, it allows you to work with metal up to 5 mm thick - for home use this power is usually more than enough.

Typically, such a device is the prerogative of professionals who are constantly faced with welding work, but at the same time it can be safely recommended to beginners who are just mastering welding strands with their own hands. The “hot start” function, protection against electrode sticking and the ability to work even during voltage surges will allow a novice welder to quickly master the basics of this craft, and a professional will always enjoy working with a good tool.

If the device allows you to regulate the voltage and current, then “by eye” what values ​​to set can be determined by the diameter of the wires and their number.

Briefly about the main thing

Welding the ends of twisted wires significantly improves the conductivity of these contacts, and therefore the characteristics of the network as a whole.

Welding machines that allow spot welding are commercially available and are also simple enough in design to make them yourself. But in the second case, simpler devices that produce alternating current are most often assembled - such devices require certain operating skills.

In practice, there is not much difference in using one device or another - if the master is experienced enough, the result will be good in any case.

Source: https://YaElectrik.ru/elektroprovodka/svarka-provodov