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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