Welder:
CD600DP — 600 watt-second capacitive discharge resistance spot welder
Attachment:
WH1125A — Opposed gap weld head with 1/8″ electrode holders
Electrode:
Top: EL125RWMA — 1/8″ Copper electrode with flat tip
Bottom: EL125TUNG — 1/8″ Tungsten electrode with wedge tip, and a “U” cutout to accept a stranded wire
Settings:
The CD600DP is set to 480ws energy with pulse 1 set to 14ws, and pulse 2 set to 466ws.
Trials/Results:
We were able to successfully weld the stranded Copper wires to the Brass pins with the CD600DP and WH1125A. Welds are placed in two spots along the Brass pin, to increase weld strength. We placed a lowered Tungsten electrode, with a wedged tip, which also carries a “U” shaped cutout to “capture” the Copper strands before and during the weld. A simple Copper electrode with a flat tip is used for the upper electrode. Due to the wire being larger than the pin, when we weld it, it does deform somewhat, and shorting between pins would be possible. We included examples of “untrimmed” assemblies, as well as “trimmed” assemblies. We simply cut away the “frayed” ends of the wires that did not fuse.
Great hold strength was achieved, however, if desired, the CD600DP’s output can be increased to get even more hold strength.
Outcome/Conclusion.
The CD600DP paired with the WH1125A is a great solution for fusing these wires to the Brass pins. The welds are easily, and quickly performed with this equipment. Set up is simple, and new users will be up and welding in minutes.
Let us know if you have any questions.
Phone: +1-801-658-0015
Toll Free Phone: 1-877-786-9353
Email: sales@SunstoneEngineering.com
Website: www. SunstoneEngineering.com