We are a company that makes OEM wire products in Canada. I just set up a jig that will eliminate the need for cropping one of our redesigned products. Our problem is finding a material that will act as a stop to keep the wires (0.144" diam. welded to 0.1875 diam.) from straying. We tried aluminum which is working as far as not welding to the product but it is not strong enough, hence, losing its functionality. We need something that is much harder, any ideas?

-- Jason Rathfelder (bitsdoo@yahoo.ca), June 15, 2001

Answers

I know someone in mexico who does the same wire weld and he uses elconite. There are various elconite materials available.

-- tom mitchell (info@atekcorp.com), June 15, 2001.

I assume that your aluminum is hard coat anodized and the hard coating scratches off. The hard coat anodize acts as an insulating barrier. However, it is very susceptible to scratching. There are many ways to located wire positions during welding. Insulated, shimable/adjustable tool steel locators can be used on adjacent sides of the welding electrode to center the wire for welding. UHMW is sometimes used where close proximity to the two (2) wires being welded require insulation from each other. Micarta (Hard-Wood Insulation) material is sometimes used. However, they are susceptible to wear. One (1) company that I know of has an injected molded locator made. The locators wear, but due to the quantities used, our customer finds it cost effective. More information would be required to provide the best solution.

-- Bob Balla (bobballa@tjsnow.com), June 18, 2001.

Dear Jason

The cropping, you elude to that I am familiar with is usually done on the edge of shelves and is a tapered back cut. Can the locator be set up to contact the butt end of the wire without contacting the cross-wire? If this can be accomplished, any type of material that can be insulated during mounting can be used. Then use insulated locators as close as possible to the weld electrode at 90 degrees to the end stop to control side to side wire position.

Stainless steel 300 or 400 series is acceptable for use as locators. The 400 series might magnetize. This may be beneficial in helping locate the part by magnetically holding the wire. This may also be detrimental if there are enough locators the magnetism sometimes- present problems loading and unloading. Therefore sometimes this magnetism creates problems in maintaining dimensional CPK tolerances. Chrome plating, although very hard, is generally a good surface for conducting electricity. This will cause pitting of the locator.

-- Bob Balla (bobballa@tjsnow.com), June 18, 2001.