Breaking the Insulation Barrier: Direct MFDC Welding of Enameled Wires

Описание: The Delicate Power of Precision: Direct MFDC Spot Welding for Enameled Wire Termination.

Terminating fine enameled wire traditionally requires precise stripping—a slow, risky step that can damage the conductor. This video demonstrates a groundbreaking application of HAIFEI MFDC Spot Welding Technology: creating a strong, reliable weld directly through the thin enamel insulation to a terminal. Witness how precise energy control enables a cleaner, faster, and more consistent process for high-value micro-assemblies.

In This Video, You Will Discover:

The “No-Strip” Process: See how the concentrated, high-current pulse of MFDC instantly breaks down the enamel insulation and simultaneously creates a metallurgical bond between the exposed copper and the terminal, all in milliseconds.

Overcoming the Challenge: The key is extreme control. The MFDC’s rapid rise time and focused energy generate heat exactly at the interface before it dissipates into the delicate wire, preventing the copper from vaporizing or the insulation from charring excessively.

Superior Joint Integrity: The result is a solid-state weld nugget that often provides a stronger and more conductive connection than soldering, with zero thermal damage to the adjacent wire insulation.

Perfect for Automation: This repeatable, high-speed process (typically less than 50ms) is ideal for automated feeding and welding systems in volume production of miniaturized components.

Why HAIFEI MFDC Excels in This Demanding Application:
This is not a standard spot welder function. It requires:

Ultra-Fine Current Control: Precise adjustment of current amplitude and pulse shape.

Dynamic Feedback: Systems to ensure consistency despite variations in enamel thickness or wire positioning.

Specialized Electrodes: Electrode design to concentrate force and current on the tiny contact area.

Ideal for Precision Industries:

Micro-Motor & Solenoid Manufacturing: Welding armature or stator windings to commutators or lead wires.

Sensor & Transducer Assembly: Creating reliable connections for strain gauges, temperature sensors, and micro-coils.

Advanced Consumer Electronics: Terminating coils in miniature speakers, vibration motors, and compact actuators.

Medical & Laboratory Device Manufacturing: Where clean, reliable micro-connections are critical.

Proven at the Cutting Edge:
HAIFEI’s technology pushes boundaries. Our work with innovators in precision engineering and electronics, supported by decades of application expertise, allows us to develop and prove such advanced processes. We provide the customized solutions that turn complex challenges into production-ready reality.

Ready to Revolutionize Your Fine Wire Assembly?
If you are an R&D Engineer, Process Developer, or Production Manager working with enameled wires below 0.5mm, this technology offers a transformative leap in quality and efficiency.

📞 Contact HAIFEI for an Exclusive Process Demonstration:
🌐 Visit Our Website: www.busbarwelder.com
📧 Email Us Directly: [email protected]
📱 WhatsApp/Call: +86 158 1641 7853

Send us your enameled wire and terminal samples. Our application engineers will conduct feasibility welds and provide you with microscopic analysis and pull-test data to prove the viability for your specific component.

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