AD-3.1 Small-to-Mid Copper & Aluminum Butt Welder
Aluminum, Brass, Bronze, Copper, Nickel
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Butt Welder
AD-4.1 Mid-Range Copper & Aluminum Butt Welder
The AD-4.1 Butt Welder steps up the AD Series for mid-range production, joining solid copper from .250 to .500 inches and stranded copper up to 250 MCM. With a higher current draw than the AD-3.1, it gives wire and cable manufacturers added headroom for thicker cross-sections without sacrificing weld quality. Its reinforced transformer, 99-step solid-state heat control, and solenoid-actuated clamps produce consistent results across aluminum, copper, brass, and bronze, all within rugged interlocked guarding designed to protect operators throughout continuous, high-volume runs.
- 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:
.250 in (6,35 mm) - .500 in (12,70 mm)
Solid Aluminum Welding Range:
.375 in (9,52 mm) - .750 in (19,05 mm)
Stranded Copper Welding Range:
2 AWG (38 mm²) - 250 MCM (126 mm²)
Solid Aluminum Welding Range:
2/0 AWG (85 mm²) - 550 MCM (283 mm²)
Max Current Draw:
730/360/290
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: 62 in (157.48 cm)
Depth to the Back: 36 in (91.44 cm)
Height: 50 in (127cm)
Weight: 1500 lbs
Width Across the Front: 62 in (157.48 cm)
Depth to the Back: 36 in (91.44 cm)
Height: 50 in (127cm)
Weight: 1500 lbs
- 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 stranded copper conductor from 2 AWG through 250 MCM in continuous wire-and-cable production
Splicing aluminum cable up to 550 MCM on coilers and payoff lines to keep production running without downtime
Welding solid copper and aluminum rod ahead of drawing or extrusion at mid-range cross-sections
Rejoining coil-end stock during production runs, where stopping the line is not an option
Producing consistent, full-cross-section welds for electrical distribution cable, industrial power assemblies, and medium MCM aluminum conductor
Real-World Benefits
- Heavy-duty transformer sustains welding current across the full mid-range capacity without duty-cycle interruptions on copper or aluminum production runs.
- 99-step SCR heat control delivers precise, repeatable settings when switching between AWG and MCM stock sizes, reducing scrap on higher-value conductor.
- Air upset with solenoid-controlled pneumatic clamps applies consistent, repeatable force on every cycle, reducing operator variation from shift to shift.
- Interlocked guarding, finger-safe components, and 24V control circuit meet modern plant safety requirements at production-grade energy levels.
- Four-piece welding die with multiple grooves, plus optional anneal, vise, and shear, keeps prep, weld, and finishing at a single station.
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-4.1 sits one step above the entry-level AD-3.1, extending the upper range from 2/0 AWG to 250 MCM copper and from 250 MCM to 550 MCM aluminum.
If your stranded stock falls within 2 AWG–250 MCM copper or 2/0 AWG–550 MCM aluminum, the AD-4.1 delivers the full AD Series architecture — air upset, 99-step SCR control, and interlocked safety guarding — at a mid-range footprint and cost. Step down to the AD-3.1 if your conductor stays consistently below 2/0 AWG copper; step up to the AD-5.1 or beyond when your production regularly pushes above 550 MCM aluminum or you need additional headroom for growth.
Best For
Wire-and-cable manufacturers and electrical component producers welding stranded copper from 2 AWG to 250 MCM and stranded aluminum from 2/0 AWG to 550 MCM who need production-grade air upset, precise heat control, and full safety guarding in a single station.
