Visual inspection criteria assure the metallurgical integrity of spot welds joining nickel leads and nickel ribbon in a 90 degree cross-wire configuration

Bryant, R. D.

English

NASA Technical Reports Server

December 1966	 Brief 66-10587 
NASA TECH BRIEF 
NASA Tech Briefs are issued to summarize specific innovations derived from the U.S. space program, 
to encourage their commercial application. Copies are available to the public at 15 cents each 
from the Clearinghouse for Federal Scientific and Technical Information, Springfield, Virginia 22151. 
Quality Control Criteria for Acceptance Testing of Cross-Wire Welds 
An investigation was carried out to establish visual 
inspection criteria for assuring the metallurgical in-
tegrity of spot welds joining nickel leads and nickel 
ribbon in a 90-degree cross-wire configuration. Qual-
ity control procedures that have been used for ac-
ceptance testing of such welds appear to be unduly 
complex and costly, and often result in the rejection of 
satisfactory units. 
The results of the investigation indicate that there 
is sufficient correlation between weld strength and 
principally two visually observable and easily meas-
urable characteristics to serve as criteria for ac-
ceptance testing of the cross-wire welds. The first 
of these characteristics, "expulsion", is the percentage 
of the total distance around a welded joint in which 
the width of the expelled weld material exceeds one 
mil. The other characteristic, "embedment", is the 
distance that the lead and ribbon are forced together 
(by heat and pressure) during welding.
Notes: 
1. Although this investigation was carried out on 
gold-plated nickel leads (16 to 32 mils in diameter) 
and bare (10x20 mil) nickel ribbons, it is believed 
that the results obtained will apply to bare nickel-
to-nickel connections spot-welded under controlled 
production conditions. 
2. Inquiries concerning this invention may be di-
rected to:
Technology Utilization Officer 
Manned Spacecraft Center 
Houston, Texas 77058 
Reference: B66-10587 
Patent status: 
No patent action is contemplated by NASA. 
Source: Russet D. Bryant 
of North American Aviation, Inc. 
under contract to 
Manned Spacecraft Center 
(MSC-627) 
Category 05 
This document was prepared under the sponsorship of the National 
Aeronautics and Space Administration. Neither the United States 
Government nor any person acting on behalf of the United States
Government assumes any liability resulting from the use of the 
information contained in this document, or warrants that such use 
will be free from privately owned rights.
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Quality control criteria for acceptance testing of cross-wire welds

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