Category Archives: WH2125

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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Stainless Steel Lap Welds with Dual Roll Spot Weld Head

System 1:
CD400DP, 400ws capacitive discharge resistance welder
WH2125A, parallel weld head (or WH1125A opposed weld head)
High pressure springs
Copper Wheel Electrodes

The WH2125A is configured with copper wheel electrodes that have been angled to fit the steel straps. This configuration was for proof of concept only and was not the ideal set-up for performing the welds. Weld head spring force is set at 8lbs for the welds pictured.

The CD400DP is set at 100ws for the welds in the video. This energy level delivers results with good pull strength and good weld nugget size. Higher energies can easily be achieved if required when welding using custom fixturing. We used the included foot pedal to intermittently actuate the welds but the CD400DP can be upgraded to include “roll spot” programming that will allow welds to be performed consecutively at pre-set intervals for as long as the foot pedal or triggering device is held down.