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TC-W100A thermocouple welder (formerly known as TCW)

The TC-W100A thermocouple welder  is easy to use and designed to operate in either a production or laboratory environment. First, select the wire gauge using the selector knob on the front panel. Then, simply load the stripped wire (1), insert the handpiece (2), and remove the welded thermocouple (3). Operators should average 5 to 10 welds per minute on a production basis, if wires are prestripped and the control is preset.

Key features TC-W100A thermocouple welder

  • Welds fresh thermocouples on demand, consistent in size and quality, and without detrimental oxide layers.
  • Perfect for medical applications to anchor arthroscopic tools.
  • May also be used to aid in the normal resistance welding of very small wires; by forming a ball on the end of the wire, more mass is given to weld the wire to something else.
  • Argon gas weld chamber for joining most thermocouple wire from 38 AWG (.004 inch/.102 mm diameter) to 20 AWG (.032 inch/ .813 mm diameter)
  • TC-W100A will make thermocouples of all commercially available thermocouple alloys including: 
    • B Platinum 30 Rh (Platinum 6 Rh),  
    • C Tungsten 5 Re (Tungsten 26 Re), 
    • E Chromel (Constantan), 
    • J Iron (Constantan), 
    • K Chromel (Alumel), 
    • R Platinum 13, 
    • Rh (Platinum), 
    • S Platinum 10 Rh (Platinum), 
    • T Copper (Constantan)
Quality control features
Weld chamber Argon gas flowing through the weld chamber ensures a reliable, oxide-free weld.
Firing circuit Prestripped wire must be properly loaded into the handpiece and the handpiece correctly inserted into the weld chamber to initiate firing. This loading sequence ensures that the handpiece is double earth grounded for maximum operator safety. Internal filt
Weld fire lockout Prevents poor welds caused by attempting a weld before the capacitors recharge. This condition exists immediately after a weld has been made or the control has been reset.
Line voltage regulator Maintains the capacitor bank voltage within ±0.25% of setting for a ±13% change in line voltage. This feature ensures consistent thermocouple weld quality.
Line failure turndown Welder automatically activates the turndown circuit, discharging the capacitor bank when the line voltage is interrupted. This circuit ensures consistent welds and protects the operator from inadvertent discharge
Power switch Disconnects both sides of the input power line when switched to the “OFF” position.
Weld ready Indicates that the capacitor bank has fully recharged and is ready to make a weld.
Wire gauge selection Controls the level of stored energy necessary to make a thermocouple weld. Energy levels are indicated for each American Wire Gauge (AWG) from 38 AWG to 20 AWG. Because of variations in he melting characteristics of thermocouple alloys, it may be necessar
Solid state circuitry Components conservatively rated when used within the maximum specified repetition rates. The charging circuit uses thyristors in a unique manner to provide high reliability and precise charging intervals.
Operating voltages and currents 115 V/0.5 A, 230 V/0.3 A, or 100 V/0.5 A at 50/60 Hz
Standby power Approximately 15 watts
Stored energy rating Range 3 to 190 watt-seconds (joules)
Capacitor bank 18,300 MFD ±10% at 20° C. Three capacitors are grouped in a single bank. At full rating, the capacitor bank is operated at 144 volts.
Welding speed As a manual feed thermocouple welder, the maximum number of welds per minute is determined by how fast the handpiece can be loaded and inserted into the weld chamber. The actual weld time is less than .1 seconds, and the time for the circuitry to recharge
Argon gas flow Recommended flow rate is 3 cubic feet per hour.
Argon gas shutoff Blocks the flow of argon gas to the weld chamber when line voltage is turned off.
Clamps (sold separately) TCWCS38 clamp for 32 to 38 gauge wire TCWCS31 clamp for 27 to 31 gauge wire TCWCS26 clamp for 23 to 26 gauge wire TCWCS22 clamp for 20 to 22 gauge wire
Powersupply Dimensions (LxWxH) 25.4 cm x 26.0 cm x 17.5 cm (10 in x 10.25 in x 6.875 in)
Powersupply Weight 7.3 kg (16.2 lb ) (includes handpiece)
Handpiece Dimensions (LxWxH) Body Length: 10.16 cm (4 in) Body Diameter: 1.91 cm (0.75 in)
Handpiece Weight 7.3 kg (16.2 lb ) (includes handpiece)
Wire clamp Dimensions (LxWxH) Length: 1.91 cm (0.75 in) Diameter: 0.64 cm (0.25 in)
Wire clamp Weight 91 gm (0.2 lb)

Customized Solutions

Send your sample to one of our technology centers in Europe for an evaluation. We will then determine which solution meets your needs best. AMADA WELD TECH offers feasibility testing and application consulting.