Welding by Metal-Electrolyte Discharge

A new welding method by using metal-electrolyte discharge has been demonstrated. This method that needs only a common 220V power supply and a common salt solution, can be used to weld metal wires and foils. At 220V, the successfully welded maximal wire diameter is 2mm, 1.5mm, and 0.3mm for Al, Fe, and Cu, respectively, in a saturated KCl solution at room temperature. At the same conditions the successfully welded maximal foil thickness is 1mm, 0.4mm, and 0.2mm for Al, Fe, and Cu, respectively. The higher voltage and higher electrolyte concentration imply higher welding ability. With further comprehensive investigation and the processing modification, this method may be developed as a simple and low-cost in situ welding method especially for metal wire connection.