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What is Electrofusion Welding? Uses and Process

Electrofusion Welding

Electrofusion welding is a specialized process that has become essential to modern manufacturing. It uses electricity to fuse two pieces of metal together, creating a strong bond that is resistant to corrosion and wear. This process also eliminates the need for manual labour, resulting in higher efficiency and reduced costs. In this article, we’ll take a look at the basics of electrofusion welding, its uses and advantages, and the process itself.

What is Electrofusion Welding?

Electrofusion welding is a type of resistance welding that uses electric current to fuse two pieces of metal together. It works by applying an electrical current across two electrodes placed in contact with the joining surfaces. The electrical current heats the electrodes and melts the metal at the point where they meet, forming a strong bond between them. The resulting weld has excellent strength and durability, making it ideal for use in a variety of applications.

Electrofusion Welding Uses

Electrofusion welding can be used for many different types of projects, including creating pipes for plumbing systems or other industrial uses, joining sheets or plates for structural purposes, and joining thin sheets or strips of metal for decorative purposes. It can even be used to join dissimilar metals, such as stainless steel to aluminium or copper to steel. Its versatility makes it an ideal choice for many different industries, including automotive manufacturing, aerospace engineering, electronics manufacturing, shipbuilding, and more.

Electrofusion Welding Process

The electrofusion welding process consists of several steps: firstly, two electrodes are placed on either side of the joint area and connected to an electrical power source; then, a high-frequency alternating current is applied across the electrodes; finally, heat builds up at the joint until it reaches its melting point (approximately 1000°C) and fuses the metals together into one solid piece. The entire process typically takes just seconds to complete depending on the size and shape of the material being welded together.


In conclusion, electrofusion welding is an efficient and cost-effective way to combine two pieces of metal quickly and easily without manual labour or additional materials like solder or fluxes needed in other welding processes. It produces strong joints that are resistant to wear and corrosion—making it suitable for use in many different industries from automotive manufacturing to aerospace engineering—and can even be used to join dissimilar metals like stainless steel with aluminium or copper with steel! If you’re looking for a reliable way to weld two pieces of metal together quickly without sacrificing quality or strength, then electrofusion welding may be just what you need!

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