Abstract: Two improvements to the electrical conductor connection disclosed in U.S. Pat. No. 4,163,869. The first is a new and improved process for forming by means of multiple timed MIG arc welding, an electrical connection between at least two lapped aluminum conductors, wherein neither conductor member has a pilot hole, thereby eliminating preforming and alignment requirements. The improved process produces the same full penetration weld with the same highly desirable substantially cylindrical weld nugget as the process of U.S. Pat. No. 4,163,869 with a preformed pilot hole does. The second improvement is a new and superior electrical conductor connection and a method of forming same between at least two lapped aluminum conductors. The connection so formed includes a weld nugget having a substantially rectangular cross-sectional configuration at the interface. The rectangular shape of the weld nugget at the interface increases the mechanical torque capacity and the electrical conductivity of the connection.

Abstract: An electrical conductor connection between at least two aluminum conductors which includes a weld nugget having a substantially cylindrical cross-sectional configuration perpendicular to the major surfaces of the aluminum conductors. The ends of the weld nugget are convexly cupped and extend outwardly past the major surfaces of the aluminum conductors to provide visual verification of joint integrity. The electrical conductor connection is formed by a method which includes providing an aperture in one of the conductors to be joined and providing a recessed backup against the other conductor, aligned with the aperture. Timed, multiple sequence MIG arc spot welding provides a weld nugget having the desired shape and diameter at the interface or throat between the two conductors. The method also enables the welding operation to be performed out of position, without sag or run of the molten pool of aluminum.