SUNSTONE PicoDC - Common Electrode Configurations; Direct weld (Opposed); Step (Adjustable Gap); Series (Adjustable Gap;Fixed Gap)

Questions? Call or Text +1-801-658-0015 • 5
e Micro Welder Experts

Direct weld (Opposed)
Current passes from one electrode through both
workpieces and out the opposing electrode. Typically
the easiest conguration to achieve good weld nuggets
and strength. See Figure 5.1.
Step (Adjustable Gap)
The electrode is placed on both materials, but from the
same side. A step or adjustable gap electrode congu-
ration can be challenging when maintain proper pres-
sure at each electrode due to possibly uneven surface.
See Figure 5.2.
Series (Adjustable Gap/Fixed Gap)
The electrodes are placed on the surface material only.
Because the current is split between both materials,
sometimes this conguration requires more weld ener-
gy than a direct weld would. See Figure 5.3.
Thermocompression
In a thermocompression conguration, the current
does not pass through the materials being welded, but
rather the current passes through the electrode tip. A
thermocompression conguration is most useful for
coated surfaces like magnet wire. See Figure 5.4.
How to Maintain Repeatable Welds
Consistent weld results require a consistent and
repeatable process. A few suggestions for ensuring
repeatable welds include:
• Keep a weld logbook documenting the process
once a successful weld has been achieved. Try
to keep track of the following:
• Force applied
• Electrodes (tip size/shape, electrode
material, etc.)
Figure 5.1. Direct
(opposed) electrode
conguration.
Figure 5.2. Step
(adjustable gap) electrode
conguration.
Figure 5.3. Series
(adjustable gap/xed gap)
electrode conguration.
Figure 5.4. Thermocom-
pression electrode cong-
uration.