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Strand Welding

Strand Welding is ideally suited for stranded tinned wires. It applies an even, intense and massive compression. As compared to ultrasonic compacting, the surface of a resistance welding wire is even and not curled.

Typical applications are sensors in the electronics industry, Y connectors in the solar and automotive industries and enamelled wires for motor and high frequency.

MacGregor Welding Systems has acquired extensive knowledge in strand welding and can offer a wide range of applications. We can provide solutions for your specific applications to join cables of a large dimension, mostly found in the automotive industry.

The two-step process consists of compacting and brazing. A proven application is a so-called intelligent battery sensor which allows battery power management. The result is a robust joint with very high strength and perfect electrical connection over product lifetime. The cable is contacted directly to the sensor tab without any additional part.

Typical Strand Welding Applications

Typical Strand Welding Applications

Strand Welding Benefits:

  • Evenly compacted compression, no individual strands in compacted area
  • Even and non-curled wire surface
  • Meets the specific welding requirements of sensors, Y connectors and enamelled wires perfectly and repeatedly


For more information and other applications, visit the compacting information page.