Please help me understand what went wrong here:
So today I finally started building my battery. I have the Malectrics spot welder on a 420A car battery. Everything was going smooth as butter. After some tests I decided to go with 30ms pulse time which made the 0.2mm Nickel strip stick to the batteries really well.
When I started welding Nickel on Nickel (the series connections, strip pieces for BMS attachment) it just wouldnt stick as nicely as it did to the battery itself. These didnt tear when I tried to pull them apart but instead the strips seperated pretty neatly. Any ideas for improvements?
Between normal welds, I suddenly had two random welds inbetween that went absolutely bonkers. Loud and bright spark and the one actually BLEW A FREAKIN HOLE THROUGH 2 LAYERS OF NICKEL AND INTO MY CELL!!! - explosing some blue plastic.
Almost lost my cool there for a second, having to tear apart an almost finished pack again in order to replace the cell
Luckily I bought 2 extra cells for blunders like this.
Can you guys please tell me what went wrong and how I can avoid it in future?