Pressure sensor assemblies join the sensing diaphragm to the housing and the housing to the process interface — the sealing welds that let the sensor hold its measurement in a pressurized medium. The diaphragm sits at tens of microns thick, so excess heat dishes it, and any dishing directly shifts range and linearity.
Pressure sensor welding covers a recurring set of joint forms:
Low heat input and a tightly focused beam produce thin-diaphragm welds without dishing the foil. Autogenous seams add no filler to the sealed cavity. Hermetic sealing applications rely on laser-quality weld consistency. Fiber and pulsed benchtop platforms both fit depending on part size and volume. See the laser line →
Arc heat is too much for production diaphragm work, but pulse arc has a role in repair — rebuilding a damaged process fitting, or tacking a component before the sealing pass. See the pulse arc line →
Two-sided access, visible surface marks and difficulty holding leak-tight seams rule out resistance spot for diaphragm work. Occasional use survives for cold-weld electrical terminal attachments away from the sealing surface. See the resistance spot line →
Because the customer’s leak-check verification is the true acceptance criterion, sample welds run through the actual customer inspection flow are the only way to lock the process choice for a specific sensor design. Continuous seam welding on enclosures, tanks, bellows and hermetic package lids — a distinct process family from the diaphragm-to-housing seal — is covered on the seam sealing application page.
Five failure modes recur across pressure sensor welding programs:
Pressure sensor welding is unforgiving — diaphragm geometry, alloy pair and downstream leak-check flow all shape the parameter window. The most reliable way to lock the process is a sample weld on the actual sensor build, run through the actual acceptance test. The evaluation itself is free.
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