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An automated apparatus for sequentially forming integrally fused battery terminals on a plurality of storage batteries is described wherein a head means having a mold means adjustably mounted thereon is automatically movable with respect to a vertical axis, and has slidably mounted thereon a burning

An automated apparatus for sequentially forming integrally fused battery terminals on a plurality of storage batteries is described wherein a head means having a mold means adjustably mounted thereon is automatically movable with respect to a vertical axis, and has slidably mounted thereon a burning means for automatically producing a variable-intensity flame for melting said battery elements to form said integrally fused battery terminal during a vertial stroke thereof. An automated post burn station is further described having a conveyor means for advancing batteries sequentially to said burning station and for aligning said batteries with respect to said station for the above described fusing process. A plurality of novel sensors incorporated into the automated post burn station facilitates the rapid, automatic processing of batteries, while providing a high degree of safety and reliability.In alternate embodiments of the present invention, members may be welded together by indirect application of heat, as for welding internal battery posts for connecting groups of plates or terminal posts electrically, through the use of a plurality of heated elements simultaneously engaging posts to be welded together, and wherein the configuration of molten metal is controlled as the weld cools, by the use of a template. The elements are heated, preferably by application of open flame through a plurality of mixing systems for the fuel, with one system being provided for each element.In both the indirect and direct heat applications relating to welding mechanisms for forming terminal posts for batteries, a novel molding means is described comprising a structural member composed of aluminum or other high heat transfer material, which is adapted to interchangeably engage an aluminum mold member which mates with the structural housing and which actually forms the voids in which the melting and casting processes take place. The mold members, which are also composed of aluminum or other high heat transfer material, are provided with a novel mold coating consisting essentially of aluminum oxide formed through an anodization process. This novel mold coating is disposed on the surfaces of the mold members which define the molding voids, and act as a thermal barrier to cause momentary delay of heat transfer from the melted terminal posts to the remainder of the mold members and their associated structural housings. This novel mold coating is described as having superior release characteristics, while facilitating the formation of high quality battery terminal posts.

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