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System:
Orion Pulse 150i - Pulse arc and resistance welder

A sharp tipped 1mm tungsten electrode is used to weld the wires. A clean, sharp electrode tip will help maintain consistent welds and ensure easy weld actuation when dealing with small wires. We used a flat copper alligator grounding clip and a pair of tweezers to hold the two wire ends during the weld. It is best to clip the ground close to the end being welded (for stability and conductive reasons). It is easiest to hold the wires at an angle to each other rather than parallel because the wires tend to ball up and draw away from the heat source. When held at an angle the molten metal can more easily form around both wires. The Argon shielding gas is set at 10psi for good coverage and flow.

Both sizes of wires are butt welded in Nano Mode with a setting of 1.0ws energy, 2.5ms Length, and with the Standard Plus ignition sequence selected. The energy setting could be increased or decreased slightly to modify the size of the ball. Too low of a setting, however, can lead to difficult actuations and weak welds. A single weld actuation is sufficient to join the two wires with good strength. Consistent ball size and shape can be achieved in a production setting by fixturing the wires for repeatable positioning and alignment with regard to the electrode.

Summary:
Nano Mode is great for welding small components that require finesse. The touchscreen user interface allows operators to quickly dial in settings and the welds can be made quickly and easily. Although we were able to achieve good results using the settings outlined, it is recommended you experiment further with your product to fine tune the settings for even better results.

Let us know if you have any questions.
Call or Text: +1-801-658-0015
Email: sales@SunstoneWelders.com
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