SICK OF BAD CONNECTIONS? SEE THE SPUT WELDER - NOW AVAILABLE

[M_D]

I have done quite a few test welds, and it does a good job of that. I had hoped to have done some test anodizing by now, but have been too busy. There is no doubt in my mind that it will allow the highest quality anodizing possible, but I still will run it through the gaunlet. There is one anodizing application in particular that I think it could be especially good for.

Even though it will leave a mark, and it will be a little large than a typical titanium racking mark, there is one difference and that is the welded connection mark would be on one surface only. Aluminum racking and bolting, etc, probably leave larger marks, so the welder will probably allow that to be improved as well as providing a better connection. An external racking clip will leave marks in a least two places, and on opposite sides. It's a lot easier to find one place where a mark won't be too detrimental, but usually it's much harder to find 2 places.

[Fibergeek]

Thanks for the input Neilfj and M_D.

Neil was the Alpha Site for the CDW; he got a prototype after I beat the bejesus out of one for a few months, then I sent him another prototype (not the same unit) and he beat the bejesus out of it. When Neil was satisfied that it really worked and had anodized using it, I "enlisted" the Beta Sites.

The Beta Sites got additional prototypes to evaluate, newly built units.

Caswell was selected for his seriously experienced salesman's "nose" (remember I'm a geek, I couldn't sell anything) and his Industry and amateur contacts. Mike think's the CDW "smells good". If you don't pass this test with a professional salesman in the Business, your product is toast.

M_D is anodizing in a real manufacturing business environment, he brings this and an expert welder's perspective. The CDW may not replace racking for many of his products and that's OK. CDW is an alternative to racking and it has it's place. M_D has made a point that I didn't consider; a blemish on one side of the work only, that's important.

The Beta Sites will yet again beat the bejesus out of the CDW, and suggest modifications/improvements, Neil already has, these were incorporated in the Beta units and his Alpha unit was also upgraded. This is how electronics development is done; or at least how I do it, tested as stringently as telecom electronics, I don't trust any other way.

I selected my Alpha and Beta Sites well, none of them will give me a break, just as this critical evaluation should be done. Well done guys, get even tougher if anything.

More to come, stay tuned.

[neilfj]

Here is a photo that shows the weld mark. The work piece is 2.5" x 1.5" x 7/8" (14.4 sq in) in size and was anodized using the LCD process at a current density of 4.5 amps. The mark on the left is the weld mark which remained when the wire was snapped off after anodizing and dyeing. The crater is slightly larger than the 8ga aluminum wire which I used, as at the time it was the only aluminum wire I had available. Using 16-18ga wire would have resulted in a much smaller crater. The hole on the right is a .125" hole that I had initially planned to use as a mechanical connection point by tapping it and screwing the 8ga wire into it.

[dagobert]

Neat little contraption. I can see where it would be great for anodizing, but what about the other side Caswells; i.e. have you tried it yet with, say, 18 gauge copper wire for making connections to small items for chrome and other plating? Having just hung a bunch of wire-wrapped nuts, bolts and widgets for a bike, I sure would have loved to have one of these for it, if it will also work with copper (or if it could be made dual purpose, by having one cap for aluminum and a second one inside it for copper?). You're the electrical wizard, Fibergeek, how much voodoo would it take to make happen?

[Fibergeek]

In electroplating no voodoo at all.

In electroplating, the connection improves as the process continues, not so in anodizing.

The very same unit does an admirable job of welding copper alloys to copper alloys, or steel alloys to steel alloys, I've done it, very easy to do. It will also weld titanium to aluminum. I can't imagine why anyone would want to do that, but you tell me.

Most welding of metals to like metals will work fine as it stands. The voltage settings will be different but within the CDW's range. The CDW does have utility in electroplating, it's just not the problem it was born to solve (I'm it's mother, I would know).

If you want to inquire in detail about a specific non-anodizing application, contact Mike or Lance Caswell, and they will put you in touch with me. Tell them I said so.

I will try your specific metals (if I haven't already) and report back to you.

[jtsuttle]

I'm ready to buy one! Any idea when they will be available? How about pricing?

[Fibergeek]

I can't answer either of your questions now. I will have more information in July. Rest assured that this product development project is going full tilt, and everything is working out better than I anticipated.

[Monkey2674]

Any New updates?

[borgen]

I am also very interested in progress on this equipment.
I've looked at this company for similar solution, specifically the battery operated mini welder.

http://www.iaid.com/acatalog/The_Man..._Units_69.html

Like the insulated plier for holding the wire.

Hope the unit discussed in this forum will be available for a good price.

Best regards,

Danny

[Fibergeek]

A little backround on what a thermocouple welder is will help:

Thermocouples are temperature sensors, commonly used to measure equipment and facility temperatures in (usually) a factory using heavy industrial processes (like a steel mill). Knowing how hot (or cold) things are getting is necessary. Welding the thermocouple to the object being monitored is common practice. Since these sensors can be located anywhere in the factory (like on pipes hanging from the ceiling) having the welder battery powered makes a lot of sense, and is also common in this type of equipment. Unfortunately since this is welding; the batteries are big, heavy, and expensive. The voltages this thermocouple welder operates at can exceed 80V, which makes them high enough to be dangerous, this thing can certainly give you a nasty electrical shock. The semiconductor switch (the SCR mentioned) is probably necessary to help avoid a shock in normal use, but at these current levels (over 1000 Amps) they aren't cheap either. If you were to use a mechanical switch, it would be as big as the switches in a Frankenstein movie.

The CDW isn't battery powered, for its intended applications this would make no sense. It operates at 50V maximum, with the majority of applications operating between 25 and 35 Volts. This keeps it at the safe level, and it has no switch in the high current path. The energy levels are similar to the thermocouple welder; which means that you probably could use the CDW to weld thermocouples, or the thermocouple welder to make anodizing and plating connections.

I didn't see any prices, but I think it would be safe to say that the CDW will be much lower in price than the thermocouple welder, just by comparing feature sets.

I appreciate your patience guys, more details will be provided soon, we are making real good progress.