Ball and Attach Wires to Steel Coil – Orion 100c

System 1:
Orion Pulse 100c, pulse arc and resistance welder

Application 1 — ball and attach stranded wires to steel ring:

A sharpened 1mm tungsten electrode is used for this application. The stranded wire is balled prior to attaching it to the coil to help ensure that all the strands are captured during the attachment weld and to create a ball of material to draw from. This step can be skipped but there is more chance of missing some strands in the weld. The stranded wire is simply held in line with the electrode and a single actuation can ball the strands together at the end.

Once the wire has been balled it is ready to be attached to the steel coil. The electrode is aimed at the joint where the ball contacts the coil. A second and third weld can be placed on the sides of the ball if desired to draw more material from the wire to the steel but care should be taken to avoid taking too much and causing necking of the joint. It is best to aim the electrode at the ball of the wire and let the molten ball attach itself to the steel. The Orion 100c is set to 17ws energy to ball and attach the 26awg wires and 22ws energy for the 20awg wire. These settings deliver strong welds without too much distortion but as you experiment further with the product you may wish to tweak the settings to obtain the ideal results.

Application 2 — ball the ends of the solid wires:
Similar to the balling of the stranded wires, the wire is held parallel with the electrode and a ball is formed in a single actuation. The size of the ball is somewhat dependent on the energy level applied. We performed welds at 60ws energy and 100ws energy, both with good balling results. The 60ws welds seem to be smoother and cleaner, however.


The Orion Pulse 100c is able to perform these sample welds quickly and easily. Pulse arc technology is ideal for joining dissimilar metals such as these copper and steel components.