Abstract
Use of electrochemical discharge (ECD) phenomenon for generating intense localized heat in a controlled manner is not unknown in the field of unconventional machining, especially when the work material is electrically non-conducting. In this paper the authors investigate the feasibility and the characteristics of microwelding using BCD. One of the major applications of microwelding is the fabrication of thermocouples using very thin wires, and this investigation is dedicated to microwelding thermocouple wires to produce satisfactory joints. It has been shown that such welds can be very conveniently achieved using ECD in a self-controlled manner. The major process parameters have been identified and their influence on the weld characteristics has been investigated. An attempt has been made to develop a theoretical model. The results are in good qualitative agreement with the experimental observations.
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