10 Years Factory 3003 H24 bright finished aluminium tread plate for Jeddah Factory
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Orion Pulse 150i, pulse arc and resistance welder
The Orion Pulse 150i is great for balling the thermocouple wires before attaching them. We balled the ends of the thermocouple you sent using 22.8ws energy, 8ms length, with sloped agitation enabled (a high frequency energy overlay that helps increase penetration and push), and standard + ignition (uses a pre-arc energy discharge to help focus the plasma and initiate welds). The size of the ball can be altered by increasing or decreasing the energy levels accordingly.
A sharpened 1mm tungsten electrode is used to weld the balled thermocouple wire to the aluminum plate. An alligator clip ground is attached to the aluminum plate during the weld. The thermocouple can be welded directly to the aluminum plate; but due to the nature of the aluminum alloy used, the welds become brittle as they cool and the thermocouple can be pulled away with little effort. To combat this we add 0.028″ sterling silver fill wire in the weld puddle. The silver acts as a “glue” and strengthens the bond between the thermocouple and the aluminum.
Welds are performed by the Orion Pulse 150i in Micro mode at 23ws energy, 8ms length, and with sloped agitation enabled. A few weld actuations around the ball will smooth the puddle and ensure good hold strength. Please note that the molten metal will tend to flow toward the point of highest heat (the tip of the electrode) so care should be taken to “aim” the electrode correctly.
It can be easier to attach the ball to an edge of the aluminum instead of the face if the application allows it.
The Orion Pulse 150i is an ideal solution for welding these samples. The touch screen user interface makes it easy for operators to quickly fine tune energy settings and find successful weld parameters. The pulse arc welding method is great for welding various types of similar or dissimilar metals and alloys such as these samples.