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.
Overview
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Review Traditional Methods
Disadvantages of Traditional Methods
Technology Behind Fusing
Fusing vs. welding
Different Fusing Methods
Fusing Advantages
Summary
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
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
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)
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
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
Microscope Image of Fused Connection
Using Tube Fusing Process
Tin (Sn) Fusing
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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.
AC Fusing Technology
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Transformer shorted across work piece
Apply low voltage (2.0 to 3.5V) and high
current (1,000 to 40,000Amps)
AC Fusing Technology
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Time controlled by line crossings –
50/60 Hz increments
Current upslope controlled by phase
shift
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
Fusing Schedule
Temp (ºF) vs. Time
Tin Fusing Methods
Methods Available for Variety of Applications
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Tang Termination
Fuse-A-Wire
Tube Fusing
Thermal Crimp
Tang Termination Method
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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
Tang Termination Advantages
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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
Fuse-A-Wire Method
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Makes direct connection between insulated
magnet wire and Tin coated lead wire
• Tin in process comes from lead wire
Patented Joyal Fusing Process
Fuse-A-Wire Advantages
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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
Tube Fusing Method
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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
Tube Fusing Advantages
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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
Tube Fuse Operations
Thermal Crimp Method
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Connection captured in a Tin coated copper
terminal
Terminal automatically made from flat strip
Patented Castech technology
Thermal Crimp Advantages
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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
Summary
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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
Summary (cont.)
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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