1. The AWE Family Includes Joyal® – A Division of AWE, Inc.
Manufacturers of resistive welding/fusing machines to connect magnet wire for all types of electro-magnetic devices including motors, generators, transformers and bobbins.

2. Overview Review Traditional Methods
Disadvantages of Traditional Methods
Technology Behind Fusing
Fusing vs. welding
Different Fusing Methods
Fusing Advantages
Summary

3. Traditional Lead Connect Methods
Strip and Cold Crimp Termination
Magnet wires have enamel removed and the wire bundle is crimped into a terminal
Strip and Braze
Magnet wires are stripped and connected by the application of heat and a brazing material
Insulation Displacement Connector (IDC)
Magnet wires are pierced by a terminal which penetrates the enamel insulation to connect to the copper wire

4. Disadvantages of Traditional Methods
Strip/Crimp
Mechanical strippers reduce cross sectional area of magnet wire
Tooling for mechanical strippers expensive and difficult to maintain
Exposed copper can oxidize and increase resistance
No process control
Increased labor required to remove insulation

5. Disadvantages of Traditional Methods
Brazed Connection
High degree of variability & inconsistency of operator
No process control
Excessive heat can cause the wires to become brittle
High cost (gas, brazing material, operator training, warranty returns, rejects)

6. Disadvantages of Traditional Methods
Insulation Displacement
Results in point contact only with higher resistance
Mechanical strength
Limited current carrying capacity
Relatively high part cost
Lack flexibility for a wide range of wire sizes in single terminal or cavity

7. Fusing Versus Welding Fusing Process
Pass current through high resistance electrodes and heat is generated at this point
Heat is dissipated into the part without melting the copper
Evaporate insulation and make a Diffusion Bond of the wires
Welding Process
Pass current through a low resistance electrode
Interface between the metals is the highest resistance and heat is generated at this surface
Metal melts and produces a weld

8. Microscope Image of Fused Connection Using Tube Fusing Process

9. Tin (Sn) Fusing Addresses all the concerns of today’s manufacturer
RoHS compliant
Fast and efficient
Highest quality connection
Feedback for process control and SPC
Minimal safety and environmental risks
Use standard tubes from various sources
Connection is strong, low resistance and most of all consistent.

10. AC Fusing Technology Transformer shorted across work piece
Apply low voltage (2.0 to 3.5V) and high current (1,000 to 40,000Amps)

11. AC Fusing Technology
Time controlled by line crossings – 50/60 Hz increments
Current upslope controlled by phase shift

12. DC Fusing
AC rectified using inverter to convert to DC

13. Tin (Sn) Fusing Process
Initial Heat to Form Tube
Approximately 180ºF
Enamel Insulation Starts to Evaporate
Approximately 450ºF
Further Heat Causes Tin to Melt & Clean Magnet Wire
Approximately 600ºF
Tin Will Eventually Evaporate
Approximately 1,000ºF
Further Heat and Pressure Creates a Diffusion Bond Between Copper Wires
Approximately 1,800ºF

14. Fusing Schedule Temp (ºF) vs. Time

15. Tin Fusing Methods Methods Available for Variety of Applications
Tang Termination
Fuse-A-Wire
Tube Fusing
Thermal Crimp

16. Tang Termination Method
Magnet wire is captured in a tang terminal
Terminal typically half hard brass and Tin coated
Typically used in bobbin and some armature applications, but can be applied to stators

17. Tang Termination Advantages
Large range of wire sizes from 0.1mm to 1.5mm
Low labor content.
Wire can be automatically placed into tang by winder and automatically fused.
Very reliable
Millions of connections made every day using some sort of tang termination
Quality improved when using Tin coating

18. Fuse-A-Wire Method
Makes direct connection between insulated magnet wire and Tin coated lead wire
Tin in process comes from lead wire
Patented Joyal Fusing Process

19. Fuse-A-Wire Advantages
Makes direct connection without need of crimp or external terminal
Process can accommodate a wide range of magnet wire/lead wire sizes
Can connect up to three (3) magnet wires to a lead wire
Process control of current, force and displacement

20. Tube Fusing Method Wires held in a Tin coated copper tube
Compatible with hundreds of existing tubes
Capable of accommodating a large variety of wire bundles
Patented Joyal Technology

21. Tube Fusing Advantages
Can be used either as a splice connection or as a lead connection
Capable of Up to 120 x 1.0mm wires in parallel
Fast – Lead bundle of 48 x 1.0mm wires can be fused within 5 – 8 seconds
Lower resistance and more consistent wire to terminal resistance than Strip and Crimp or Brazed connection
Very little operator training required

22. Tube Fuse Operations

23. Thermal Crimp Method
Connection captured in a Tin coated copper terminal
Terminal automatically made from flat strip
Patented Castech technology

24. Thermal Crimp Advantages
Capable of terminating larger wire bundle compared to Fuse-A-Wire
Inexpensive terminal material available from a variety of sources
Flexible - Single terminal strip can accommodate wide range of wire bundles
Fast Change-over Between Wire Bundles

25. Summary
While many manufacturers are reluctant to change, fusing is a proven technology
Tin fusing offers more opportunities to improve product consistency and quality
Manufacturing processes would be simplified with improved flexibility
Fusing would resolve many safety and environmental issues
Feedback for process control and SPC not offered with present methods

26. Summary (cont.)
Justifications based on these improvements would be difficult with today’s “Rate of Return” and “Payback” requirements
With the additional benefits of reduced labor, training, setup, repair and warranty costs, the justifications should be simple
The variety of Tin fusing methods available, can be applied to wide range of applications