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The WH1125A is configured with a ¼” copper lower electrode that has an 1/8″ mounting shank and is notched at the tip to accept the diameter of the steel rods. An 1/8″ copper upper electrode is used (one end is tapered to 1/16″ for the smaller wire diameter and the other end is flat for the larger wire diameter). The spring force is set to 10lbs for all the welds pictured.
The 0.025″ wire is welded by the CD400DP set with Pulse 1 off, Pulse 2 at 200ws, and Total Energy at 200ws. The coating on the metal causes extra sparking and makes the welds somewhat rough; but the welds are strong and hold up under torsional stress. The lower electrode may need extra periodic cleaning due to the coating.
The 0.005″ wire is welded with Pulse 1 off, Pulse 2 at 50ws, and Total Energy at 50ws. These settings deliver strong results, but they could be tweaked further to obtain your desired ideal weld characteristics as you experiment further with your product.
The CD400DPand WH1125A are ideal for welding the wire to the steel pins. The CD400DP has ample energy for the diameter of wires you sent.