Welding Near Batteries. There are a few vehicles now where the manufacturers DO require disconnecting the battery on newer vehicles last two to three model years but along with that they also require disconnecting several harnesses as well. If you connect the work lead adjacent to where the weld will be done there shouldnt be a problem.
Resistance welding is well suited to welding nickel tab material up to 0015 thickness and nickel or steel clad copper tab material to around 0012 thickness to a wide variety of terminal materials. I use pure nickel strip. I show this and more.
With arcing you can burn a hole in the battery which is not good.
Make sure the battery is disconnected and all systems are shut down before the welding process. There are a few vehicles now where the manufacturers DO require disconnecting the battery on newer vehicles last two to three model years but along with that they also require disconnecting several harnesses as well. Sunstone s CD400DP Capacitive Discharge 400 watts seconddual pulse spot welders combined with Sunstones WH2125 Parallel weld head with 0125 Copper Electrodes are the perfect battery tab spot welding systems for battery pack rebuilding assembly and manufacturing. The price may be higher but this price does not seem unreasonable.