I need to weld five 36 gauge type T thermocouples at right angles to a length of 28 gauge nickel 200 wire for a test fixture I am building.
Which is a bit nasty to begin with, but here's the real kicker. I have to weld the two thermocouple wires to each other and the carrier 28 gauge wire while remaining stacked perpendicularly. That is, the copper has to weld to the nickel, and then the constantan has to weld to the copper, but not to the nickel wire below it. Or the stack could run the other way around, nickel to constantan to copper.
That part of it is kicking my butt. I have a Unitek HF25 resistance welder, so I have pretty decent control of the weld parameters, but fixturing it to stay neatly stacked is proving... problematic.
Does anyone here do this level of stupid small stuff on a daily basis and either have ideas or just want to do it? I'm thinking laser welding might be a better approach, but I don't have a laser welder.
I only need two of these assemblies ever. I hope.
Thanks
John
Which is a bit nasty to begin with, but here's the real kicker. I have to weld the two thermocouple wires to each other and the carrier 28 gauge wire while remaining stacked perpendicularly. That is, the copper has to weld to the nickel, and then the constantan has to weld to the copper, but not to the nickel wire below it. Or the stack could run the other way around, nickel to constantan to copper.
That part of it is kicking my butt. I have a Unitek HF25 resistance welder, so I have pretty decent control of the weld parameters, but fixturing it to stay neatly stacked is proving... problematic.
Does anyone here do this level of stupid small stuff on a daily basis and either have ideas or just want to do it? I'm thinking laser welding might be a better approach, but I don't have a laser welder.
I only need two of these assemblies ever. I hope.
Thanks
John