Category Archives: Wire to Pad

Micro Welding – 32awg Magnet Wire and 3mil Nickel Tabs to Gold Tabs

System 1:
DCD320 – DC and CD resistance welder (high precision power supply)
MWH3000 – 3000g parallel micro weld head
/>Tungsten thermo-compression electrode (flat rectangular tip)
8awg weld cables


System 2:
CD100SPM – 100ws CD resistance welder
WH2125A – Parallel weld head (or WH1125A opposed weld head)
1/8″ copper electrodes with tips stepped down to 1/16″
1awg weld cables

DCD320 and MWH3000 Magnet Wire Welds:
Similar to the original samples we welded, magnet wire is attached to each of the gold pads to provide electrical contact between the two. We used two wires per set of tabs. The DCD320 is set with Pulse 1 at 20ms, Pulse 2 at 50ms, and Peak Voltage at 2.5v. The MWH3000 micro weld head is set at 1750g force and is configured with a tungsten thermo-compression electrode in the parallel electrode holder. We used 32awg magnet wire instead of the 36awg to decrease the resistance.

CD100SPM and WH2125A Step Welds:
We attempted the step weld technique without the thin film. Unfortunately, we had similar results to the last test. The vertical edge of the upper pad is just too thin to withstand the energy required to bond the two pads together. We set the CD100SPM to 8ws energy and no bond took place. At 9ws energy, the vertical “Side B” popped and split. The coating on edge B needs to be much thicker for the step weld to function properly.

CD100SPM and WH2125A Step Welds and Nickel Tab Welds:
Just as a re-visit for further evaluation, we used 0.003″ thick nickel tabs to bridge the electrical gap between “Surface A” and “Surface D” using the CD100SPM and a WH2125A weld head. We used two copper 1/8″ electrodes that have tips stepped down to 1/16″. The spring force on the weld head was set to 10lbs.

45ws Energy30ws Energy
We set the CD100SPM to maximum pulse width and 45ws energy to weld the nickel tab to “Surface A” using a single weld actuation. Since the lower section is narrower we dropped the energy down to 30ws to avoid blow outs. The resulting welds are clean and look nice. We left the tabs long during welding for easier handling and cut them to length after welding.

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Solar Cells – Copper Ribbon to Terminal and Braided Copper Wire

System 1:

CD320DPM2, 320ws CD resistance welder
DPHP, dual probe hand piece
1/8″ Tungsten electrodes (tips tapered to 0.05″)

We performed these sample welds using a dual probe hand piece set-up for ease of access to the tabs. Two 1/8″ tungsten electrodes were used with their tips tapered to 0.05″ diameter. Hand pressure becomes important in this situation since too little pressure can cause arcing and too much pressure can damage the tabs or cause the welds to be weak.

The CD320DPM2 was set to 150ws energy to quickly and easily weld the two tabs to the rectangular terminals. On the second tab one of the weld attempts caused a blow-out due to misalignment of the electrode (the tip of the electrode rested over the gap in the terminal). The other tabs were welded to the braided copper wire at 140ws energy. Resulting welds are strong but you can fine tune the settings with further experimentation to fit the desired parameters.