The simplest ways to connect high resistance alloy wires

How to connect wires of nichrome, constantan, manganin and other high resistance alloys

For connecting wires made of high-resistance alloys (nichrome, constantan, nickeline, manganin, etc.), there are several simplest methods of welding without the use of special tools.

The ends of the wires to be welded they clean, twist and pass through them with such force that the junction is red hot. A piece of lapis (silver nitrate) is placed in this place with tweezers, which melts and welds the ends of the wires.

If the diameter of the alloyed wire with high welding resistance does not exceed 0.15 — 0.2 mm, then a thin copper wire (with a diameter of 0.1-0.15 mm) is wound around its edges and the insulation cannot be removed from the rheostat wire. The wires thus connected are then introduced into the flame of the burner. At the same time, the copper starts to melt and firmly connects the two resistor wires.The remaining ends of the copper wire are cut off and the weld is insulated if necessary. This method can be used to connect copper wires to high resistance alloy wires.

Burnt wire on the winding of the rheostat or heating device can be connected as follows: the ends of the wire at the break point are pulled by 15 — 20 mm and polished to a shine. Then a small plate is cut from sheet steel or aluminum, a sleeve is made from it and placed on the wires of the junction. The wires are pre-fastened with a simple twist. The sleeve is then pressed tightly with pliers. Connecting wires with a sleeve provides sufficiently high mechanical strength, but the contact at the junction is not always reliable, and this can lead to local overheating of the wire and its burning.