12-30-2023, 03:46 PM
The initial' success' with 0.15 copper and 0.1mm nickeled steel sandwiches depended on sharper welding pen tips, the sanded steel 18650 can devoid of nickel plating, and the infinite slot method.
The copper would tear and leave some dots behind, but little itty bitty dots on cell and tiny pinholes in the removed copper strip.
Not adequate for Esk8 stress and vibration, but likely fine for a laptop battery, where the less resistance would not really be beneficial or worth the extra effort.
For an Ebike battery in a hard case, the little pinprick welds likely be adequate.
I just did some more experimentation with the fatter tips, a full charged Lipo
O.15 copper, 0.10 NpS, no slot, 98ms pulse: fail
0.15 copper, 0.10 NPS with slot 98ms pulse 75% success.
0.09 copper 0.15 pure nickel, no slot 90 ms pulse, hard fail
0.09 copper 0.15 pure nickel slottted 90 ms pulse. Fail.
0.09 copper, 0.10 NpS no slot 70 ms pulse Solid success.
The infinite slot ahould allow less than a 70 ms pulse on 0.09 cu and 0.10nps, reducing welder and battery stress, but is so much extra work, effort and the slot itself is reducing total cross section of conductive sandwich, that it makes little sense.
Now, my Lipo is a 3s 5.2 amp hour 80c rated (bullsheet) Zee brand. The cheaPest Lipo brand available, and by all accounts of RC nerdom on youtube, the worst performer.
Could I weld 0.15 copper with a more respected brand of lipo, or with another one in parallel, perhaps.
Could 8 awg leads to and from welder make the difference? maybe.. Shorter would be difficult to manage.
Do I need to weld 0.15 copper 0.10MM NPS in this 10s2p battery? Absolutely not.
If I could, what would the benefit be?
Some unknown number of milliwatthours would goto electric motors instead of heating the conductors.
The battery would stay a bit cooler. and thus last for and unknown amount of additional cycles.
I'd have some unknown degree of extra power and range, but the difference could be so small, as to be statistically insignificant.
Replacing the fake xt60 connector and 16awg from ESC circuit board, with 12awg and an authentic XT90 connector, could be more beneficial, although that was planned anyway.
Have I convinced myself that I need to go no farther, in the pursuit of less electrical resistance?
Probably not.
The copper would tear and leave some dots behind, but little itty bitty dots on cell and tiny pinholes in the removed copper strip.
Not adequate for Esk8 stress and vibration, but likely fine for a laptop battery, where the less resistance would not really be beneficial or worth the extra effort.
For an Ebike battery in a hard case, the little pinprick welds likely be adequate.
I just did some more experimentation with the fatter tips, a full charged Lipo
O.15 copper, 0.10 NpS, no slot, 98ms pulse: fail
0.15 copper, 0.10 NPS with slot 98ms pulse 75% success.
0.09 copper 0.15 pure nickel, no slot 90 ms pulse, hard fail
0.09 copper 0.15 pure nickel slottted 90 ms pulse. Fail.
0.09 copper, 0.10 NpS no slot 70 ms pulse Solid success.
The infinite slot ahould allow less than a 70 ms pulse on 0.09 cu and 0.10nps, reducing welder and battery stress, but is so much extra work, effort and the slot itself is reducing total cross section of conductive sandwich, that it makes little sense.
Now, my Lipo is a 3s 5.2 amp hour 80c rated (bullsheet) Zee brand. The cheaPest Lipo brand available, and by all accounts of RC nerdom on youtube, the worst performer.
Could I weld 0.15 copper with a more respected brand of lipo, or with another one in parallel, perhaps.
Could 8 awg leads to and from welder make the difference? maybe.. Shorter would be difficult to manage.
Do I need to weld 0.15 copper 0.10MM NPS in this 10s2p battery? Absolutely not.
If I could, what would the benefit be?
Some unknown number of milliwatthours would goto electric motors instead of heating the conductors.
The battery would stay a bit cooler. and thus last for and unknown amount of additional cycles.
I'd have some unknown degree of extra power and range, but the difference could be so small, as to be statistically insignificant.
Replacing the fake xt60 connector and 16awg from ESC circuit board, with 12awg and an authentic XT90 connector, could be more beneficial, although that was planned anyway.
Have I convinced myself that I need to go no farther, in the pursuit of less electrical resistance?
Probably not.
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