Copper Wires Cross Welded

System 1:
CD100SPM, 100ws CD resistance welder
WH1125A, air actuated opposed weld head
1/8″ Tungsten upper electrode with a slightly tapered flat tip
Copper grounding plane lower electrode

The WH1125A is configured with an 1/8″ tungsten electrode (with a tip that has been slightly tapered) in the upper holder and a copper grounding plane electrode in the lower holder. The weld head is set to approximately 5lbs force for the welds pictured. The wires are positioned below the upper electrode in a slight crossing pattern to ensure connection during the weld

The CD100SPM is set to 22ws energy at max pulse length to attach the copper ribbons together. This setting delivers a strong hold and provides electrical continuity between the two wires.