Skip to content

Sandia Advanced Adaptive Aluminum Resistance Welding Capability

Sandia National Laboratories

Adaptive Resistance Welding of Aluminum Alloys

Processing/Manufacturing

Description

Sandia National Laboratories has the ability and process understanding to use advanced wave synthesis to generate high direct current (DC) pulses coupled with a frictionless ram system that produces resistance welds in aluminum stems and tubes for high-pressure gas reservoirs. Using adaptive welding controls, the system has proven to be capable of developing alloy projection welded stems and pinch welds on aluminum alloys 2219 and 3003.

Capability Bounds

Welding currents are limited to 150 kA DC. Limits on cross-sectional areas that can be welded have not been established but are expected to be in the range of 75–100 mm2.

 

Unique Aspects

Advanced waveform synthesis technology has been combined with adaptive feedback control to develop a unique resistance welding capability for aluminum alloys. The capability allows for welding with millisecond feedback control at currents up to 150 kA, a frictionless actuator, and process diagnostics for weld dynamic response characterization. The capability has been demonstrated on projection welding of fill stems on pressure vessels and closure pinch welding of aluminum tubes. 

This capability is located within SNL’s limited area. As such, access is subject to security clearance requirements.
Sandia photo

Test a Proof of Concept in Your Factory

Not convinced the WeldComputer Control will work for you? Test it out in your facility on your machine and see for yourself!

With our evaluation offer, the WeldComputer team will work with you to temporarily hook up a fully functioning welding control to your weld machine so you can see the results for yourself, without having to make a capital equipment investment to see proof. Let us help you solve your power, welding quality, and/or control reliability problems, and prove it to you on your own equipment.

Copyright © 2025 WeldComputer Corporation. WeldComputer, WeldView, and WeldAware are registered trademarks of WeldComputer Corporation.

WeldComputer technology is protected by the following U.S. Patents: 4,714,913 4,742,473 4,803,331. Other Patents Pending.