AD-3.1 Small-to-Mid Copper & Aluminum Butt Welder
Aluminum, Brass, Bronze, Copper, Nickel
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Butt Welder
AD-6.1 High-Capacity MCM Cable Butt Welder for Copper & Aluminum
The AD-6.1 Butt Welder marks the move into Micro Weld’s heavy-frame lineup, handling solid copper up to 1.000 inch and stranded copper to 1000 MCM. Mounted on a stout 4,800-pound truck with stationary mounts, it brings the rigidity needed for large-conductor work in wire, and cable production. A heavy-duty transformer, 99-step heat control, and an interlocked weld flash containment hood combine to deliver powerful, clean welds on aluminum and copper, with comprehensive interlocked guarding and 24-volt controls safeguarding operators on the most demanding jobs.
- 480 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:
.500 in (12,70 mm) - 1.000 in (25,40 mm)
Solid Aluminum Welding Range:
.625 in (15,80 mm) - 1.375 in (34,92 mm)
Stranded Copper Welding Range:
250 MCM (126 mm²) - 1000 MCM (506 mm²)
Solid Aluminum Welding Range:
400 MCM (202 mm²) - 1250 MCM (642 mm²)
Max Current Draw:
1150/920
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: 85 in (215.90 cm)
Depth to the Back: 40 in (101.6 cm)
Height: 50 in (127cm)
Weight: 4800 lbs
Width Across the Front: 85 in (215.90 cm)
Depth to the Back: 40 in (101.6 cm)
Height: 50 in (127cm)
Weight: 4800 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
Welding large-section stranded copper from 250 MCM to 1000 MCM in utility-grade and industrial power cable production
Splicing heavy aluminum conductor up to 1250 MCM on continuous coiling and payoff lines serving infrastructure and grid-scale projects
Joining large solid copper and aluminum rod stock ahead of extrusion, rolling, or heavy drawing operations
Maintaining uninterrupted production runs on large-section power cable by eliminating coil-end downtime
Processing oversized non-ferrous conductor where flash containment, interlocked guarding, and 24V control circuits are required by plant safety protocols
Real-World Benefits
- Purpose-built for large MCM work — the heavy-duty transformer and 4,800 lb frame handle the sustained energy demands of 1000 MCM copper and 1250 MCM aluminum.
- Interlocked weld flash containment hood and finger-safe electrical components address the elevated safety requirements of high-energy, large-section welding in busy production environments.
- 99-step SCR heat selection gives process engineers precise repeatable heat settings across materials, conductor sizes, and shifts.
- Solenoid-controlled pneumatic upset delivers the consistent clamping force that oversized conductor demands for uniform, repeatable welds on expensive stock.
- Integrated anneal option softens large-section weld zones in-line, critical for maintaining ductility in conductor that will be bent, formed, or terminated downstream.
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-6.1 marks a significant step up from the AD-5.1 — stranded copper capacity extends to 1000 MCM and aluminum to 1250 MCM, while machine weight increases to 4,800 lbs, reflecting the heavier transformer and frame required at this energy level.
If your conductor consistently runs below 750 MCM aluminum or 550 MCM copper, the AD-5.1 handles that range with a smaller footprint. Choose the AD-6.1 when your production regularly calls for large-section MCM cable, or when plant safety requirements demand the additional interlocked enclosure and flash containment features standard on this model. Step up to the AD-8.1 or AD-10.1 for the largest solid and stranded sections in the series.
Best For
Utility cable manufacturers, large-section power cable producers, and heavy industrial wire operations welding stranded copper up to 1000 MCM and aluminum up to 1250 MCM — facilities where process consistency, flash containment, and multi-shift reliability are non-negotiable.
