AD-4.1 Mid-Range Copper & Aluminum Butt Welder
Aluminum, Brass, Bronze, Copper, Nickel
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Butt Welder
AD-3.1 Small-to-Mid Copper & Aluminum Butt Welder
The AD-3.1 Butt Welder is one of Micro Weld’s most versatile production welders for joining copper and aluminum wire, rod, and stranded conductor. Designed for demanding wire and cable manufacturing environments, it handles solid copper from .187 to .375 inches and stranded copper from 4 AWG through 2/0 AWG, providing a broad working range for many common conductor applications. An extra heavy-duty transformer, solid-state heat control, pneumatic clamping and upset, and comprehensive interlocked guarding provide the durability, control, and safety required for reliable day-to-day production.
- 480 or 600 volts, 60 cycle, single phase a/c
- Robust fixed & movable interlocked guarding
- Solid state heat control
- Solenoid controlled, pneumatic actuated clamps
- Four piece welding die with 2-3 grooves included
- Interlocked Electrical Enclosure
- 24 Volt Control Voltage
- “Finger safe” Electrical Components and covers
- Interlocked Weld Flash Containment Hood
- Heavy duty truck with stationary mounts
Metal:
Aluminum, Brass, Bronze, Copper, Nickel
Construction:
Solid, Stranded
Solid Copper Welding Range:
.187 in (4,76 mm) - .375 in (9,52 mm)
Solid Aluminum Welding Range:
.250 in (6,35 mm) - .500 in (12,70 mm)
Stranded Copper Welding Range:
4 AWG (27 mm²) - 2/0 AWG (85 mm²)
Solid Aluminum Welding Range:
2 AWG (38 mm²) - 250 MCM (126 mm²)
Max Current Draw:
390/195/160
Single Phase Transformer:
Yes
Heat Selection Method:
99 STEPS SCR
Upset Method:
Air
Air Requirements:
100psi
Mounting Truck Type:
4 Wheels
Dimensions & Weight:
Welding Die Height: 43 in (109.22 cm)
Width Across the Front: 42 in (106.68 cm)
Depth to the Back: 36 in (91.44 cm)
Height: 50 in (127cm)
Weight: 1350 lbs (612.23 kg)
Width Across the Front: 42 in (106.68 cm)
Depth to the Back: 36 in (91.44 cm)
Height: 50 in (127cm)
Weight: 1350 lbs (612.23 kg)
- Integrated Anneal
- Standard Vise
- Heavy Duty Vise
- Shear
Butt Welder Upgrades to Improve Your Precision and Productivity
Upgrade your Micro Weld butt welders with world-class safety & technology accessories. You’ll get the same quality, rugged welders with the safety features you need, creating uniformity with every machine and consistency with every training.
- New Finger Safe Covers & Components
- 24V Control Circuit
- Interlock Switch on Rear Access Panel
- Solid-State Heat Control
Applications
Joining medium-gauge copper and aluminum conductors in continuous wire-and-cable production
Splicing stranded copper building wire and industrial power cable from 4 AWG through 2/0 AWG
Welding solid copper and aluminum rods ahead of drawing or forming operations
Rejoining coil-end stock on the payoff and take-up lines to maintain production continuity
Producing clean, full-cross-section welds on aluminum up to 250 MCM in fabrication and production environments
Real-World Benefits
- Heavy-duty transformer delivers consistent welding current across mixed non-ferrous jobs without duty-cycle stalls on copper or aluminum stock.
- 99-step SCR heat control gives operators fine, repeatable heat selection — reducing guesswork and scrap when switching between materials or conductor sizes.
- Air upset with solenoid-controlled pneumatic clamps applies uniform force every cycle, removing operator variation from weld quality.
- Interlocked guarding, finger-safe components, and 24V control circuit keep a production-grade machine aligned with modern plant safety standards.
- Four-piece welding die with multiple grooves, plus optional anneal, vise, and shear, lets one station handle prep, weld, and post-weld finishing.
Comparison to Similar Models
Within the AD Series, capacity steps up with the model number, from the AD-3.1 through to the AD-10.1. The AD-3.1 is the first model in the range, built for solid copper and aluminum from .187–.375 in and .250–.500 in respectively, and stranded conductor from 4 AWG to 2/0 AWG copper and up to 250 MCM aluminum. If your stock falls within those ranges, the AD-3.1 delivers the same air upset, SCR heat control, and safety architecture as the larger AD models — at a lower cost and in a smaller footprint. Step up to the AD-4.1 or beyond when your conductor sizes exceed the AD-3.1’s upper range, or when you need additional capacity headroom for future production growth.
Best For
Producers of small-to-mid-size copper and aluminum conductor — wire-and-cable manufacturers, electrical component shops, and fabrication operations — welding solid and stranded stock in the 4 AWG to 250 MCM range who need production-grade air upset and safety guarding without top-of-range capacity.
