As two parts are pressed together with high force, a high current pulse is released through the parts. The projection, critical to the parts weldability, heats to a plastic state and material from both work pieces mix resulting in a diffusion / forge-type bond of fine grain. Parent material strengths are typically achieved without the segregation and re-crystallization problems associated with fusion-type welding processes. The precise charging level provides precise ready-to-assemble parts at high production rates with no part distortion.

A second pulse is used for most high carbon steels. This second pulse produces ultra-fine cementite precipitates from the rapidly cooled BCT Martensitic weld structure and effectively tempers the weld zone.

The Capacitor Discharge welding process (also known as High-Speed Pulse Welding) forms a diffusion or forge-type weld. Rapid metal bonding (approximately 10 ms) causes minimal part heating producing a weld without distortion, discoloration or normalization. Capacitor Discharge welding is similar to resistance welding (AC, spot welding).

Capacitor Discharge welding achieves the diffusion weld using a focused, high current pulse at low voltage. The energy for the pulse is derived from charged capacitors. A precision voltage level controlled to less than 1% variation isolates the welding supply from fluctuations in the power grid. No cover gases are required.

Weld parameters and response variables are monitored, controlled and recorded to assure consistent weld quality. These include pre-weld height, energy, pressure, peak current, temper current, upset, etc. Weld energy compensation routines are added to keep constant weld current with temporal changes in the work area. A part is either accepted or rejected based on these measurements creating a high confidence in weld quality.