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PA welding machines command attention with their efficient design and construction. The manual clamping device with optimized ergonomics is the basis for this robust but also inexpensive version.

In SE as well as PA welding machines, the wire rope or cable ends are inserted into a tube made of ceramic or graphite until the ends touch. Ceramic is the material of first choice here. As a rule, we use graphite tubes from > 400 mm² (version G).

After starting the welding process, the two ends are welded together by the current which then flows and the upset force which is applied. Optionally, preheating is carried out to achieve an optimal temperature profile. After completion of the weld, the tube is broken off. The surface at the weld is burr-free, clean, smooth and only imperceptibly thicker.

Operation of STRECKER welding machines is easy to learn. The pneumatic welding clamping fixture is standard equipment starting with the SE12 and meets the highest demands in terms of convenience and ergonomics (the same applies for the PA100-SE). The upset pressure is then also pneumatic. The compact and robust machine design with intuitive operator guidance is designed for industrial use in production.

MS and MK welding machines are designed for larger cross-sections, the highest quality and documented reproducibility with wire ropes and cables of up to 2500 mm² made of aluminium or copper. We meet the highest requirements for the smallest possible single-wire setups, class 2 to class 6 applications, as well as for high-strength alloys. Even wire ropes with different diameters can be welded with a minimized heat-affected zone. The burr is removed in the welding clamping fixture and caught in the machine. The result is a homogeneous, very thin and pore- and burr-free connection. The MS and MK series are equipped with our innovative FullParameterControl (FPC) control system as standard. The complete welding recipe is stored safely and with accurate repeatability in the controller. All settings of the machine are made automatically according to the recipe selected with no operator intervention. As an option, the quality of the welding process can be monitored with the STRECKER parameter monitoring system.

A 3-phase direct current transformer is employed to counteract the high current consumption or short-term peak load that occurs when welding very large conductor cable cross-sections. This reduces the current consumption.

The SE welding machine series is designed for the effective joining of stranded wires and conductor cables made of aluminium or copper in tubes. We specify the clamping jaw required for each size or setup. This means that even with the smallest possible single-wire setups, we meet the highest requirements, for example, for the automotive industry.

These machines are also found in front of extruder lines, as the optimal welding results with minimal thickening facilitate a smooth workflow. Even wire ropes of different diameters can be welded. The result is a homogeneous, pore- and burr-free connection.

The wire rope and cable ends are inserted into a tube made of ceramic or graphite until the ends touch. Ceramic is the material of first choice here. As a rule, we use graphite tubes from > 400 mm² (version G).

After starting the welding process, the two ends are welded together by the current which then flows and the upset force which is applied. Optionally, preheating is carried out to achieve an optimal temperature profile. After completion of the weld, the tube is broken off. The surface at the weld is burr-free, clean, smooth and only imperceptibly thicker.

Operation of STRECKER welding machines is easy to learn. The pneumatic welding clamping fixture is standard equipment starting with type SE12 and meets the highest demands in terms of convenience and ergonomics (the same applies for type PA100-SE). The upset pressure is then also pneumatic. The compact and robust machine design with intuitive operator guidance is designed for industrial use in production.

As an example, using active weld parameters as outlined in the table depicted, employing a five-step recipe to weld a 50mm2 copper wire to a copper terminal requires less energy and lower power to perform the weld than a one-step recipe. The result shows that it’s possible to weld larger cross-sections with less power using closed loop technology:First, no sonics are applied. The sonotrode is lowered and the start height is measured.

Because closed loop control (CLC) produces highly precise and consistent measurements, there are advantages including:Missing material detection on wire harness. During the process of manufacturing wire harness, the blade responsible for cutting and stripping might cut strands from the wire. This may affect both electrical and mechanical properties. This means a high degree of detection of any issues is crucial. With closed loop control system, the detection rate for missing material is as low as 3%, versus conventional ultrasonic welding in which the rate is closer to 5 to 7%.

Missing/bent foil detection. With foil stack welding, it’s critical to have the correct number of foils welded. Having them straight is vitally important, as well, as a bent or misplaced foil might cause a short circuit to occur. The CLC process and the precision sensors detect both missing and bent foil with extreme accuracy.

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As an example, using active weld parameters to employ a five-step recipe to weld a 50mm2 copper wire to a copper terminal requires less energy and lower power to perform the weld than a single-step process. The result shows that it’s possible to weld larger cross-sections with less power using CLC:In step one, no sonics are applied. The sonotrode is lowered, a defined force is applied, and the start height is measured.

Selecting an incorrectly sized welding cable can be dangerous. The wires can overheat and burn the insulation layer, which leads to electric shocks and fires.

Durability and flexibility are crucial aspects of welding cables. They must be resistant to cuts, wear, and insulation damage and flex and bend easily. You need to manipulate the welding electrode with ease and access every part of the welded joint. Imagine how difficult welding would be if the cables were too stiff.

Copper is a better conductor than aluminum. So, aluminum-core welding leads require a larger cable diameter than copper-core leads. But, aluminum is lighter and less expensive than copper.

EPDM and neoprene are preferred insulators for welding cables because of their flexibility and ruggedness. These materials endure abrasion, moisture, and dust and are good at preventing cuts and insulation breaks.

Welding cable size depends on the maximum amperage output of the welding machine, the rated output duty cycle, and the total length of the welding circuit. But the current type (AC or DC) does NOT affect the welding cable size.

You may have heard that the cable length determines the cable size, but this is only half true. You need to take the entire welding circuit into account. This includes both welding leads, the ground clamp and the electrode holder.

Some ampacity calculations rate cables only based on the cable length and wire diameter, which is not the most accurate way to calculate the cable size. As we discussed above, you need to consider the whole circuit length.

But, as the welding cable diameter increases, the ampacity rating rises. There is less resistance to the electrical current flow if the cable’s cross-section is larger. Less resistance means cooler cable, which increases the ampacity rating.

Every welding machine is rated for an operating duty cycle. This percentage rating notes the portion of a 10-minute interval the welder can run at a specified amperage before resting for the remainder of the time.

The larger the cable diameter, the higher the allowed ampacity. Thin and long welding cables cannot carry high currents because there is too much resistance, causing the cable to overheat and damage its insulation. This is dangerous and can lead to fires, burns, or electrical shocks, especially since you are likely to make physical contact with the cable as you weld.

Complex calculations to select the cable size involve the machine’s duty cycle, maximum amperage output, circuit length, and cable diameter. Luckily, cable sizing charts simplify the process. But, before we show you a table covering most welding needs, we must discuss the wire gauge rating.

Cables are typically categorized by an American wire gauge (“AWG”) size. The AWG rating works in reverse — the smaller the AWG number, the larger the cable’s diameter. For example, AWG 20 cable has a far smaller diameter than AWG 5 cable.

Extension cables work similarly to welding cables. Essentially, you need a cable that can handle the welder’s input amperage and voltage for the desired extension cable length.

Many tool stores sell welding cables, but it’s easiest to get them on Amazon because of the wide selection. We link to commonly used cables below, but you should know that welding leads are sold either standalone or with an electrode holder, ground clamp, lugs, and DINSE plugs.

If you buy cables at the welding stores, you have the advantage of buying by the foot. But, if you buy on Amazon and similar online stores, you will usually get a fixed length. Still, it’s more convenient to get the cables online, and you can save the extra length for other needs.

This 100 ft. welding cable comes with a high-quality 300A Tweco ground clamp and 250A electrode holder. It also includes DINSE plugs and standard Tweco 2-AF Lugs if your machine doesn’t use DINSE connectors. The cable is AWG 1/0 gauge (AWG zero, as discussed earlier).

Many people don’t need a 100 ft. welding circuit, but this cable is still a popular choice because you can trim it and save the rest for future needs. Your welding leads are bound to break at some point, so it’s good to have a spare cable for replacement.

Welding cables must have an adequate diameter for your specific setup. The cable length, amperage, machine’s duty cycle, and the cable’s insulation rating dictate the necessary size.