Resistance Welding of thin Aluminum

[zora65]

I'm looking for information regarding resistance (seam welding?) of a thin aluminum sheet/foil parts (approx .005" thk). Part "A" is a drawn case with a flange around the edge that is .094" wide and Part "B" is a flat piece. I need to achieve a hermetic seal on the completed part.

I am admittedly way out of my element on this project and have the following questions;

1. Is this possible?
2. What are the pitfalls/drawbacks to this approach?
3. Any special design considerations for the weld area?
4. Any special preparation of the aluminum (i.e. oxidation)?
5. What is the best aluminum for this? I was thinking 1100.
5. Would laser welding be a better approach?

I am also searching for a company to do the welding for us. If anyone knows of some companies providing this service I would appreciate the info.

Thanks for any and all comments!



Bsilk
Senior Designer

 

[Goahead]

As you are ready to outsource, would you consider the possibility of using ultrasonic welding? It seams more suitable, given the thickness ratio range. Equipment manufacturers would possibly develop the process for you.

http://www.welding-advisers.com/

 

[griffengm]

Zora,
Is the entire assembly made of .005" thick material with one piece having a flange broke to .093"?
Would you consider an adhesive?

Griffy

 

[zora65]

Goahead and griffengm,
I appreciate both of your responses. I've bookmarked the welding advisers website for futrue refernce and found quite a bit of useful information there. As luck would have it, my project is two part. A prototype stage and then (after the usual learn by doing) a potential production stage. A few minutes before reading the latest post we settled on using an adhesive for the prototype. I have also identifed what I believe is a source for either seam sealing or welding a production part (we were questioning if the ultrasonic weld would provide the required hermetic seal).Fortunately, a question for another day. Thanks again for the input.

Bsilk
Senior Designer