Thermocouple Welders

Thermocouple welders are specialized resistance welding power supplies designed specifically for joining thermocouple wires and temperature sensor assemblies. These systems create uniform bead junctions between dissimilar metals used in thermocouples, producing a consistent weld bead without detrimental oxide layers and preserving sensor performance.

How Thermocouple Welders Work

Thermocouple welder technology combines a capacitor discharge (CD) power supply and

Tungsten Inert Gas (TIG) welding technology to fuse thermocouple wires at the junction without excessive heat input.

In these systems, energy is stored and then rapidly released to form the weld bead. This controlled discharge supports consistent weld bead size and quality, helping maintain sensor response characteristics.

Capabilities of Thermocouple Welders

Thermocouple welders provide manufacturing capabilities that include:

  • Welds fine thermocouple wires across a full range of commercially available alloys, even at small gauges such as 38 AWG to 20 AWG
  • Creates a uniform bead junction that is consistent in size and quality
  • Reduces detrimental oxide layers at the junction through controlled energy delivery
  • Operates in both production and laboratory environments with straightforward setup and use

These capabilities support manufacturing of accurate, reliable thermocouples that are suitable for temperature sensing applications in industrial, research, and quality systems.

Typical Applications

Thermocouple welders are used in applications such as:

  • Fabrication of thermocouple sensors used in temperature measurement
  • Welding fine gauge wires where precision joining is required
  • Producing bead-type junctions that influence sensor performance and response time

Thermocouple Welders

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