AD-3.1 Small-to-Mid Copper & Aluminum Butt Welder
Aluminum, Brass, Bronze, Copper, Nickel
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Butt Welder
AD-5.1 MCM Copper & Aluminum Production Butt Welder
The AD-5.1 Butt Welder bridges Micro Weld’s compact and large-frame models, welding solid copper from .375 to .750 inches and stranded copper up to 550 MCM. Its substantially larger transformer and higher current capacity suit operations processing heavier wire and cable and requiring greater production capacity. Solid-state heat control and pneumatic clamping ensure uniform, dependable welds across aluminum, copper, and other non-ferrous metals, while the interlocked guarding and finger-safe components keep demanding production environments both efficient and safe through extended operation.
- 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:
.375 in (9,52 mm) - .750 in (19,05 mm)
Solid Aluminum Welding Range:
.500 in (12,70 mm) - .875 in (22,20 mm)
Stranded Copper Welding Range:
2/0 AWG (85 mm²) - 550 MCM (283 mm²)
Solid Aluminum Welding Range:
250 MCM (126 mm²) - 750 MCM (385 mm²)
Max Current Draw:
1450/720/580
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: 1700 lbs
Width Across the Front: 62 in (157.48 cm)
Depth to the Back: 36 in (91.44 cm)
Height: 50 in (127cm)
Weight: 1700 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
Running stranded copper conductor from 2/0 AWG through 550 MCM on continuous wire-and-cable production lines
Splicing aluminum cable up to 750 MCM on the payoff and take-up equipment without pulling the line down
Welding solid copper and aluminum rod at larger cross-sections ahead of drawing, extrusion, or roll-forming operations
Handling coil-end joints on heavier-gauge power cable where weld quality directly affects downstream processing
Supporting high-volume output on utility-grade and industrial power distribution cable in the mid-to-upper MCM range
Real-World Benefits
- A transformer rated to 1,450A maximum current handles the extra thermal demand of larger copper and aluminum cross-sections.
- Fine 99-step SCR heat selection keeps operators in control across a wide material mix — critical when running both copper and aluminum at MCM sizes where scrap is costly.
- Pneumatically actuated, solenoid-controlled clamping applies consistent, repeatable upset force on every cycle, for uniform welds on high-value stock.
- Interlocked fixed and movable guarding meets modern plant safety requirements at the higher energy levels this machine operates at.
- The optional anneal station softens weld zones in-line, eliminating a secondary operation and keeping the production cycle tight.
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-5.1 is the first model in the range where stranded copper capacity reaches 550 MCM and aluminum extends to 750 MCM — making it the natural choice for operations that have outgrown the AD-4.1’s upper limit. If your conductor falls within the AD-4.1’s applicable ranges — stranded copper from 2 AWG to 250 MCM or stranded aluminum from 2/0 AWG to 550 MCM — the AD-4.1 covers that work at a lower cost and weight. Move up to the AD-6.1 or beyond when your production calls for copper above 550 MCM or aluminum pushing past 750 MCM, or when you want additional headroom without re-tooling.
Best For
Wire-and-cable manufacturers and power distribution cable producers running stranded copper from 2/0 AWG to 550 MCM and aluminum up to 750 MCM — operations that need the thermal capacity and consistent upset force to maintain weld quality at higher MCM sizes across multi-shift production.
