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System:
CD1000DP – 1000ws capacitive discharge resistance welder
WH1125A – Opposed air actuated weld head
1/8″ tungsten upper electrode (wedge shaped tip with notch)
1/8″ copper lower electrode (tapered to 0.075″)
1awg weld cables
The WH2125A is configured with a tungsten 1/8″ upper electrode that has a wedge shaped tip (0.07″ width) and a notch cut out to help gather the copper strands; and a 1/8″ copper lower electrode that is tapered to 1/16″. 1awg weld cables are used and the spring force is set to 15lbs for the weld pictured. The stop nut gap is set to 3/8″.
The same welder settings were used for all four samples. The CD1000DP is set with Pulse 1 at 100ws, Pulse 2 at 400ws, and Total Energy at 500ws.
The settings outlined above are a good starting point and provide good pull strength; but further experimentation with weld energy, spring force, and electrode tip shape can lead to even better results.
Summary:
The CD1000DP and WH1125A are an ideal solution for attaching the braided cable to the plated brass components. The notch in the tip can be removed if desired for a flatter weld spot, but the strands may spread out more. Higher energies are available if the pull strength needs to be increased.
Let us know if you have any questions.
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Email: sales@SunstoneEngineering.com
Website: www. SunstoneEngineering.com