The Ideal Option For Thermocouple Welding

Thermocouples play a crucial role in temperature measurement, utilizing the current generated by heating one end of two dissimilar metals. These sensors are known for their high accuracy and can be designed using a wide range of metals and corresponding calibrations. While general-use thermocouples employ base metals for the two dissimilar wires, noble metal thermocouples are preferred for high-temperature applications. Achieving precise welds between these wires and the thermocouple components is vital for ensuring measurement accuracy and device performance. Thermocouple welding is a critical process in constructing and assembling thermocouples, which are indispensable in various industries, from electronics to industrial temperature control. These reliable temperature sensors accurately record a broad range of temperatures and are available in diverse shapes and sizes to accommodate different requirements.

858 Front Panel
858 Front Panel

Percussion Welder has developed specialized technology that makes thermocouple welding much easier than ever before. Instead of guessing if there is a good point of contact between your material and thermocouple, our technology ensures you have a secure connection without any guesswork. It eliminates having to adjust the power output or apply additional finishing touches as you go, allowing you to quickly create stable connections so you can move on to the next project. This innovative system allows for greater efficiency and accuracy in thermocouple welding, which leads ultimately to better products and increased customer satisfaction with the results.

Thermocouple Welding Options

Percussion Welder offers a precise, accurate, and controlled option for percussion welding of thermocouples. Unlike other thermocouple spot welders, our Percussion Welder system offers increased weld strength and performance with a bonded weld that is strong and durable. Our thermocouple wire welder uses both heat sources and pressure to fuse the molten ends of the two delicate wires for a butt weld that does not require filler, solder, or crimping. Percussion Welder is the ideal option for thermocouple welding due to its precise control of both heat and pressure. This technology uses an electrical arc to generate a spark, which melts both ends of the wire at the same time. The pressure applied is light and consistent, making sure that there is no damage to either wire’s hardness or resistance.

The low application of pressure and the precise heating of the ends of the wire does not impact the resistance or the hardness of either of the wires. By controlling the gap and the timing of the electrical arc and percussion, the welds are consistent, ensuring quality welding on a low or a high-volume level. The Percussion Welder can also be integrated with automation, providing efficient thermocouple welding techniques for any manufacturing and industrial processes.


Picking Percussion Welder for your thermocouple welding is a popular choice because it offers a level of control, accuracy, and precision that is unmatched by any other welding method. With its ability to be integrated into automated processes, manufacturers can now achieve consistent welds with minimal effort and cost. The produced welds are robust, trustworthy, and long-lasting, making them an ideal option for high-temperature applications.

Percussion Welder is an excellent choice when considering welding thermocouple solutions. Our technology sets a new standard for control, accuracy, and precision, surpassing all other welding methods. With the added benefit of integration into automated processes, manufacturers can achieve consistent, top-quality welds with minimal effort and cost. Trust in our robust and long-lasting welds, making them the ideal solution for high-temperature applications.


Contact us today and experience the unmatched excellence of thermocouple welding.

Adjustments & Features of the
Model 858 Front Panel

858 Front Panel

Actuator: The actuator setting
controls the charging voltage of the
capacitors that energize the
electromagnetic actuators. The range is
0 to 150 volts. The actuators move
the weldments together
during the welding process.

Delay: The delay is 0.5 to 5.0
milliseconds between actuator
initiation and discharge
of weld energy.

Weld: The weld energy voltage
control determines the charging
voltage applied to the
weld capacitors. The range
is 0 to 150 volts.

Mode: There are two mode settings,
regular and heavy-duty.
Heavy Duty adds an additional
bank of capacitors to
the weld output.

Pulse: The long / short pulse
width switch provides the
operator with pulse
width control. A long pulse
delivers less peak energy
for a long time
than a short pulse.

Polarity: Controls the direction of
weld energy electron flow.
The direction of electron flow
affects the amount of
heat applied to each weldment.

Capacitance: This setting controls the
amount of capacitance in the
weld output circuit. There
are three capacitance
ranges labeled 1, 2 and 3.

Operation so simple and intuitive on model 858, we can show you how to use it in less than 60 seconds

If you’re like us, sometimes a picture (or video) is worth a thousand words. Watch our 60-second video showing you step-by-step how easy Percussion Welder 726 Bench fixture is to operate.

Follow us on Instagram

Follow us on Instagram

For more demos, slow-mo’s, and closeups of the action.

Let's Talk

No matter what your micro-welding challenge is, the Percussion Welder team at MTI Microwelding is available to offer guidance, answer questions, and even run live, in-person tests using our equipment.

See Potential? Let's Discuss Your Application

After exploring the advantages of percussion welding for small components, are you eager to see how it could benefit your specific application? Schedule a 15-minute consultation with our experts to discuss your project and explore the possibilities!