I have measured the ESR of my welder and its much lower than anticipated. The ESR of the welder bus bars at the front of the welder measures less than 0.0005 Ohm (500 micro Ohm). With such low resistance, this welder can produce astronomical currents and will only be limited by the resistance of the probe, wire and material being welded.
I am way behind schedule with my version 3 processor and spent most of my time getting the new welder built.
Most companies and people out there that are welding A123's are very tight lipped about how they do it and I would like to get to the bottom of it!!! I'm doing some experiments with inverted resistance welding and was wondering if there are some of you guys that would send me some of your old A123's to play with ??? I will post all my findings on here!!!