Off subject, kind off: home brew spot welding NiCd batteries

Miroslav Pokorni All Messages By This Member #7231 Hello everyone, Does anyone have an experience with spot welding tabs on a subC size NiCd batteries? I have a stack of ten batteries which were connected with nickel plated iron (?) tabs, welded at four spots at each end of tab, but a tab came loose on one cell. I was thinking of using large cap (10,000 mictoF or so), charged to 50 V or so, a suitable switch (perhaps mercury displacement) and short, thick and solid wires as electrodes. I need to make only four welds, so 'electrodes' can be consumable. I do not intend to break any new grounds, looking for someone's prior experience. Thank you in advance, Miroslav Pokorni
Eric Schumacher #7235 Hello Miro Best deal is to use an activated flux (acid) you need so little flux on the tip of the solder that you can't even see it. Just tin the nickel plate or stainless of the cell and finish the job with the usual 63/37. The stainless conducts so poorly that it takes practically no heat (in calories) to get the job done. The admonishment not to solder to nicads must have been started by a guy who tried to do it with a 500 watt iron and rosin core solder, will never happen that way. Acid core solder doesn't work very well by the way but the flux that tastes like lemon juice (we use it on our SMT line) works great. Eric toggle quoted message Show quoted text At 04:07 PM 3/20/04, Miroslav Pokorni wrote: Hello everyone, Does anyone have an experience with spot welding tabs on a subC size NiCd batteries? I have a stack of ten batteries which were connected with nickel plated iron (?) tabs, welded at four spots at each end of tab, but a tab came loose on one cell. I was thinking of using large cap (10,000 mictoF or so), charged to 50 V or so, a suitable switch (perhaps mercury displacement) and short, thick and solid wires as electrodes. I need to make only four welds, so 'electrodes' can be consumable. I do not intend to break any new grounds, looking for someone's prior experience. Thank you in advance, Miroslav Pokorni Yahoo! Groups Links
gettingalongwouldbenice All Messages By This Member #7238 --- In TekScopes@..., "Miroslav Pokorni" <mpokorni2000@y...> wrote: Hello everyone, Does anyone have an experience with spot welding tabs on a subC size NiCd batteries? I have a stack of ten batteries which were connected with nickel plated iron (?) tabs, welded at four spots at each end of tab, but a tab came loose on one cell. I was thinking of using large cap (10,000 mictoF or so), charged to 50 V or so, a suitable switch (perhaps mercury displacement) and short, thick and solid wires as electrodes. I need to make only four welds, so 'electrodes' can be consumable. I do not intend to break any new grounds, looking for someone's prior experience. Thank you in advance, Miroslav Pokorni There's currently a thread in sci.electronics.design on the subject. I posted some links to my spot welding experiments and some commercial data. mike
Brooke Clarke All Messages By This Member #7281 Hi Miroslav: If this is for making a battery pack for the Tek 1500 series Metallic Cable Tester, see my battery Adapter at: I've found that using today's rechargeable Ni-MH "AA" cells the run time is better than the factory times using 20+ year old Sub-C size Ni-Cad batteries. Have Fun, Brooke Clarke, N6GCE From: "gettingalongwouldbenice" <gettingalongwouldbenice@...> toggle quoted message Show quoted text To: TekScopes@... Subject: [TekScopes] Re: Off subject, kind off: home brew spot welding NiCd batteries Date: Sun, 21 Mar 2004 03:38:22 -0000 --- In TekScopes@..., "Miroslav Pokorni" <mpokorni2000@y...> wrote: > Hello everyone, > > Does anyone have an experience with spot welding tabs on a subC size NiCd > batteries? I have a stack of ten batteries which were connected with nickel > plated iron (?) tabs, welded at four spots at each end of tab, but a tab > came loose on one cell. > > I was thinking of using large cap (10,000 mictoF or so), charged to 50 V or > so, a suitable switch (perhaps mercury displacement) and short, thick and > solid wires as electrodes. I need to make only four welds, so 'electrodes' > can be consumable. > > I do not intend to break any new grounds, looking for someone's prior > experience. > > Thank you in advance, > > Miroslav Pokorni

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Off subject, kind off: home brew spot welding NiCd batteries