Micro resistance Welding

Lynn Welding's Micro-resistance welding capabilities originated from a specific customer need. Initially, the request was to weld a .004” thick stainless-steel foil patch onto an existing metal-encapsulated insulation blanket attached to a sophisticated military exhaust system. The successful patching of fatigue cracks in this exhaust system was crucial to prevent scrapping the entire unit. Lynn Welding utilized its Amada 1000 ADP Advanced Capacitive Discharge Welders to develop a repair procedure, which was subsequently approved by the United States Air Force.

The facility maintains a variety of welding heads and handheld units in stock to perform a wide range of welds at any given time. Micro-resistance seam welding heads are primarily used for hermetically sealing thin foils, while micro-resistance welding press heads are employed for joining terminal connections in sensitive electrical components. This welding method is ideal for applications involving sensitive electronics that cannot withstand the heat generated by soldering processes.

Recently, Lynn Welding was contracted by a major defense contractor to micro-resistance spot weld a .011” diameter spring onto a gyroscopic guidance component. These springs were integral for providing stabilization during impact events, highlighting the critical nature of the welds. The micro-resistance welding process was chosen for its reproducibility, durability, and reliability. Lynn Welding routinely handles foil and wire thicknesses ranging from .0005” to .015” using micro-resistance welding techniques.

• Wires and Foils
• Honeycomb Welding (for pre-braze positioning)
• Sensitive electronics
• Hermetic sealing of foils using the micro-resistance seam welding process.
• Small electronic and mechanical components
• Lighting Components
• Battery Tabs
• Sensors
• Motor connections
• Miniaturized components.
• Joining in heat sensitive areas