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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 and the wires are grounded using an alligator clip or brass tweezer ground attachment.
It is helpful to ball the tips of both the stranded wires and the sensor lead wires before attempting to attach them to the thermocouple wires.
The stranded wire is balled using the Orion Pulse 150i set in Micro Mode at 12ws energy with Sloped Agitation enabled (a high frequency energy overlay that increases penetration) and the standard plus ignition sequence selected (provides a focusing pre-arc only available in the Orion I series welders that helps initiate the weld discharge). The size of the ball can be altered somewhat by raising or lowering the energy level accordingly (the higher the energy, the bigger the ball).
The sensor lead wires can be balled at 3ws energy with no agitation overlay. This step is not absolutely necessary but it helps during the attachment process because there is more material to draw from and the disparity in size between the thermocouple wire and the lead wire is decreased (leading to minimized necking).
The thermocouple wires can be balled together at 12ws energy with sloped agitation.
After balling the stranded wires they can be butt welded to the thermocouple wires using a setting of 12ws energy, sloped agitation, and standard + ignition. This setting could be increased slightly but we usually start with lower settings to avoid blowing through the wires. Two or more welds can be made (one on the top and one on the bottom ideally) for maximum strength.
The sensor wires are welded to the thermocouple wires at 3ws energy in Nano Mode.
Let us know if you have any questions.
Call or Text: +1-801-658-0015
Email: sales@SunstoneWelders.com
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