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My current hypothesis is the nickel strip material that came with my spot welder is actually nickel plated steel, so it may have more resistance and therefore burn off. I put a test piece in salty water and it showed a few streaks of rust forming.
I could buy pure nickel strips and see if that fixes the issue. I could also try doubling the strips up... or I could just solder thinner gauge copper wire directly to the battery.
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