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System 1:
Orion Pulse 150i, pulse arc and resistance welder

A half-blunted 1mm tungsten electrode is used to weld the lead wires. We were able to find acceptable weld settings for all five variations of wire.

We used the following settings for each wire type:

20awg Bare Copper -- 25ws Energy, 8ms length, Sloped Agitation (a high frequency energy overlay that helps increase penetration), and "Standard +" ignition sequence

20awg Phosphor Bronze -- 20ws Energy, 8ms Length, Sloped Agitation, "Standard +" Ignition

24awg Tinned Jumper -- 15ws Energy, 8ms Length, Sloped Agitation, "Standard +" Ignition

18awg Tinned Bonded Copper -- 29ws Energy, 8ms Length, Sloped Agitation, "Standard +" Ignition

18awg Tinned Copper -- 27ws Energy, 8ms Length, Sloped Agitation, "Standard +" Ignition

Brass Terminal to Brass Terminal Edge Weld -- 27ws Energy, 8ms Length, "Standard +" Ignition

The Orion Pulse 150i can quickly and easily weld the wires in several different locations/configurations.

Brass terminal to brass terminal edge welds:
Welds can be placed along the edge of the joint where the two terminals mate. It is a good idea to weld both sides but not necessary. Once the terminals have been edge welded a lead wire can be easily attached to the tips of the terminals for great strength and quality.

Lead wire to tip of terminals:
This is the easiest location to attach the wires. The wire and the tip of the terminal are quickly balled together in a single weld actuation and the wire can be placed on the inside edge or outside edge of the terminal. This type of weld also exhibits the highest strength since there is no necking of the wire and full fusion can take place. The wire can be welded to both of the terminal tips to help reduce torsional failure/increase rigidity if desired.

Lead wire to edge of terminals:
This is also a fairly easy weld to make but it requires a few weld actuations per side to obtain optimal weld strength.

Let us know if you have any questions.
Call or Text: +1-801-658-0015
Email: sales@SunstoneWelders.com
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Lead wire to base of terminals:
This location can be tricky to achieve ideal weld strength since necking can occur and wire placement can be difficult. The welds can also be placed in the rounded area of the terminal if desired.

Summary:

The Orion Pulse 150i is ideal for performing the welds on these samples. The touchscreen user interface allows operators to quickly dial in settings and the welds can be made quickly and easily.

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