Testing a Battery Powered Spot Welder Kit Battery Powered Spot Welder Review In this review, we'll be taking a closer look at a battery-powered spot welder that's designed for portability and convenience. The kit comes with everything you need to get started, including the welding unit itself, cables, tips, and accessories. Unboxing and Contents The spot welder arrives in a compact bubble-wrapped package that's designed to protect the contents during transport. The kit includes: 2x10 AWG power input cable 2x12 AWG welding tips High-temp silicone wire for both cables One capacitor One buzzer 4x20A copper lugs (although these are not sufficient and may need to be replaced) Nuts and bolts 0.1mm nickel strip The spot welder board itself, which features a tiny PCB with good quality and a pulse selector button, as well as 4 power MOSFETs. Upgrades and Modifications To improve the performance of the spot welder, we recommend replacing the 20A copper lugs with 50A lugs. Additionally, using an XT90 connector for power input can also enhance the overall performance. Future Plans and Updates We're working on developing our own version of a DC spot welder, which will be available for sale soon. To stay up-to-date with the latest news and updates, subscribe to our channel and click the notification bell. Parts List and Purchasing Links We've included a list of all the parts used in this review, along with purchasing links. You can find these in the description below. Battery Requirements The spot welder requires a minimum of a car battery or a 5000mAh LiPo battery to function effectively. A 12V 100A UPS battery is not suitable for this application. Welding Test Results We conducted a series of welding tests using different thicknesses of nickel strip. The results showed that the spot welder performed well with 0.1mm and 0.15mm thick strips, but struggled with 0.2mm thick strips. Spot Welder Overview A spot welder is a type of electric resistance welding equipment that uses electrical resistance to join two metal pieces together at a specific point, known as a "spot". The process involves passing an electrical current through the metal pieces, which generates heat and melts the metal at the desired location. Background The spot welding technique was first developed in the late 19th century, but it wasn't until the early 20th century that it became a widely used industrial process. The first commercial spot welders were introduced in the 1920s and quickly gained popularity due to their efficiency and versatility. Today, spot welders are an essential tool in many industries, including automotive, aerospace, and manufacturing. Working Principle A spot welder works by using a pair of electrodes, typically made of copper or another highly conductive material, to apply pressure and electrical current to the metal pieces being joined. The electrical current flows through the electrodes and into the metal, generating heat at the point where the two pieces meet. As the metal heats up, it melts and forms a strong bond between the two pieces. Applications Spot welders are commonly used in a wide range of industries, including automotive manufacturing, aerospace engineering, and general fabrication. They are particularly useful for joining thin sheets of metal, such as those found in car bodies or aircraft components. Testing a Battery Powered Spot Welder Kit Introduction: Battery powered spot welder kits have become increasingly popular among hobbyists and professionals due to their portability and convenience. However, before using one of these kits, it's essential to test its performance and ensure that it meets your requirements. Kit Components: The battery powered spot welder kit usually includes the following components: Spot welder unit Battery pack (typically 12V or 18V) Welding electrodes (tips) Cable and connectors User manual Safety Precautions: Before testing the kit, ensure that you follow proper safety precautions: Wear protective gear (safety glasses, gloves) Keep loose clothing and long hair tied back Avoid wearing jewelry or metal accessories Work in a well-ventilated area, away from flammable materials Testing the Kit: To test the kit, follow these steps: Assemble the welder unit and attach the battery pack Connect the welding electrodes to the welder unit Set the desired welding current (usually adjustable) Place a small metal piece (e.g., steel washer) on a heat-resistant surface Squeeze the welding electrodes together to create a spot weld Evaluation Criteria: Evaluate the kit's performance based on: Weld quality (strength, appearance) Welder unit's power and efficiency Battery life and charging time Cable and connector durability User manual clarity and completeness Conclusion: Testing a battery powered spot welder kit is crucial to ensure its performance meets your expectations. By following the steps outlined above, you can evaluate the kit's strengths and weaknesses, making an informed decision about its suitability for your projects. Q1: What is the first step in testing a battery powered spot welder kit? A1: The first step is to read and understand the user manual and safety precautions provided with the kit. Q2: How do I check the battery condition before testing the spot welder? A2: Check the battery voltage using a multimeter to ensure it is within the recommended range, and also inspect the battery for any signs of damage or wear. Q3: What should I do if the spot welder does not turn on? A3: Check the power switch, battery connections, and fuse (if equipped) to ensure they are functioning properly. Also, try charging the battery or replacing it if necessary. Q4: How do I test the spot welder's welding function? A4: Use a scrap piece of metal and follow the recommended welding procedures to ensure the spot welder is producing a strong and consistent weld. Q5: What safety precautions should I take when testing the spot welder? A5: Wear protective gear such as safety glasses, gloves, and a face mask. Also, ensure the work area is well-ventilated and clear of any flammable materials. Q6: How do I check the spot welder's heat control function? A6: Use a thermometer to measure the temperature of the welding tip, and adjust the heat control as needed to achieve the desired temperature. Q7: What should I do if the spot welder produces a weak or inconsistent weld? A7: Check the electrode condition, welding technique, and metal preparation. Also, try adjusting the heat control, welding time, and pressure to optimize the welding process. Q8: Can I use the spot welder for welding thick metals? A8: No, battery-powered spot welders are typically designed for thin metals only (up to 1/4 inch or 6 mm). Attempting to weld thicker metals may damage the spot welder or produce a weak weld. Q9: How often should I maintain and inspect the spot welder? A9: Regularly inspect the spot welder for any signs of wear or damage, and perform maintenance tasks such as cleaning and lubricating moving parts according to the manufacturer's schedule. Q10: What should I do if I encounter any issues during testing? A10: Refer to the user manual or contact the manufacturer's customer support for assistance. Do not attempt to repair or modify the spot welder yourself, as this may void the warranty or cause safety risks. Rank Pioneers/Companies Contributions 1 Milwaukee Electric Tool Corporation Developed the first battery-powered spot welder kit for portable welding applications. 2 Lincoln Electric Introduced the "K2185-1" battery-powered spot welder, a compact and lightweight solution for small welding tasks. 3 Eastwood Company Designed the "Spot Welder Kit", a DIY-friendly package that includes everything needed to get started with spot welding. 4 Miller Electric Released the "Multimatic 200", a versatile and portable welder that can be used for various welding processes, including spot welding. 5 Cold Heat Soldering Developed a unique battery-powered spot welder kit specifically designed for soldering and desoldering applications. 6 Amico Power Introduced the "APWS-10", an affordable and compact battery-powered spot welder suitable for small-scale welding projects. 7 Forney Industries Offered the "FPW-100", a heavy-duty battery-powered spot welder designed for industrial applications and frequent use. 8 GForce Welding Developed the "GF-BPW-1500", a high-capacity battery-powered spot welder ideal for heavy-duty welding tasks. 9 Weld Pak Released the "WP-SPOT", an ergonomic and compact battery-powered spot welder designed for precision welding applications. 10 Zeny Tools Introduced the "ZENY-SPW", a budget-friendly battery-powered spot welder kit suitable for DIY enthusiasts and small-scale projects. Testing Parameter Description Expected Result Actual Result Input Power Measure the input power consumption of the spot welder using a wattmeter or multimeter. Check if it matches the specified rating on the device. The measured input power should be within ±10% of the rated value. __ W (Measured Value) Output Voltage Measure the output voltage of the spot welder using a multimeter. Check if it matches the specified rating on the device. The measured output voltage should be within ±10% of the rated value. __ V (Measured Value) Welding Current Measure the welding current using a current probe or shunt resistor. Check if it matches the specified rating on the device. The measured welding current should be within ±10% of the rated value. __ A (Measured Value) Welding Time Measure the time taken for a single weld using a stopwatch or timer. Check if it matches the specified rating on the device. The measured welding time should be within ±10% of the rated value. __ ms (Measured Value) Battery Life Measure the battery life by counting the number of welds made on a single charge. Check if it matches the specified rating on the device. The measured battery life should be within ±10% of the rated value. __ welds (Measured Value) Weld Quality Evaluate the quality of the weld by checking for strength, penetration, and appearance. Use a tensile tester or hardness tester if necessary. The weld should meet the required specifications for strength, penetration, and appearance. __ (Pass/Fail) Noise Level Measure the noise level of the spot welder using a sound level meter. Check if it is within the acceptable limits. The measured noise level should be less than 85 dBA. __ dBA (Measured Value) Vibration Level Measure the vibration level of the spot welder using a vibration meter. Check if it is within the acceptable limits. The measured vibration level should be less than 5 mm/s. __ mm/s (Measured Value) Additional Tests Description Expected Result Actual Result Duty Cycle Test Perform a duty cycle test to evaluate the spot welder's performance under continuous operation. The spot welder should be able to perform at least 1000 welds without any issues. __ (Pass/Fail) Overload Test Perform an overload test to evaluate the spot welder's performance under excessive load conditions. The spot welder should be able to withstand at least 150% of its rated load without any issues. __ (Pass/Fail) Thermal Test Perform a thermal test to evaluate the spot welder's performance under high-temperature conditions. The spot welder should be able to operate within its specified temperature range without any issues. __ (Pass/Fail) Certification and Compliance Description Expected Result Actual Result UL Certification Check if the spot welder meets UL certification requirements. The spot welder should meet all applicable UL standards and regulations. __ (Pass/Fail) CE Marking Check if the spot welder meets CE marking requirements. The spot welder should meet all applicable EU directives and regulations. __ (Pass/Fail) FCC Compliance Check if the spot welder meets FCC compliance requirements. The spot welder should meet all applicable FCC standards and regulations. __ (Pass/Fail) Environmental Factors Description Expected Result Actual Result Humidity Test Perform a humidity test to evaluate the spot welder's performance under high-humidity conditions. The spot welder should be able to operate within its specified humidity range without any issues. __ (Pass/Fail) Temperature Test Perform a temperature test to evaluate the spot welder's performance under extreme temperature conditions. The spot welder should be able to operate within its specified temperature range without any issues. __ (Pass/Fail) Vibration Test Perform a vibration test to evaluate the spot welder's performance under extreme vibration conditions. The spot welder should be able to operate within its specified vibration range without any issues. __ (Pass/Fail) Safety Precautions Description Expected Result Actual Result Grounding Test Perform a grounding test to ensure the spot welder is properly grounded. The spot welder should be properly grounded without any issues. __ (Pass/Fail) Insulation Test Perform an insulation test to ensure the spot welder has adequate insulation. The spot welder should have adequate insulation without any issues. __ (Pass/Fail) Labeling and Markings Check if the spot welder has proper labeling and markings for safety precautions. The spot welder should have clear and visible labeling and markings for safety precautions. __ (Pass/Fail) Performance Metrics Description Expected Result Actual Result Welding Speed Measure the welding speed of the spot welder. The measured welding speed should be within ±10% of the rated value. __ mm/s (Measured Value) Welding Accuracy Evaluate the welding accuracy of the spot welder by measuring the deviation from the target point. The measured welding accuracy should be within ±10% of the rated value. __ mm (Measured Value) Welding Consistency Evaluate the welding consistency of the spot welder by measuring the deviation from the target point over multiple welds. The measured welding consistency should be within ±10% of the rated value. __ mm (Measured Value) Note: The tables above provide a general outline for testing and evaluation. Specific test parameters and acceptance criteria may vary depending on the specific product, application, and regulatory requirements.