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W9GFX
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Attaching a Resistor Between Two Stainless Rods

06/30/2009 8:20 AM

I need advice/recommendation as to how to attach a resistor between two stainless rods in an "H" configuration where the resistor is the cross-member and the stainless rods are the vertical elements. The rods are approximately 3/16 inch in diameter and are right against the resistor body. Thanks in advance.
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Anonymous Poster
#1

Re: Attaching a resistor between two stainless rods

06/30/2009 8:29 AM
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Anonymous Poster
#2

Re: Attaching a resistor between two stainless rods

06/30/2009 10:52 AM
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Electronic Wiz
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#3

Re: Attaching a Resistor Between Two Stainless Rods

06/30/2009 10:44 PM

First off, stainless steel is a problem but before we get into that, can you give more information on the resistor. Is it a power resistor? What kind of terminals does it have? What is the power rating? If it is an axial leaded resistor <=25 watts, you may be able to use a clamp termination, perhaps something similar to the terminals in the #1 reply. If you are talking 50 watts or bigger with larger terminals, soldering is very difficult with stainless and is not readily suggested.
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plancette
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#4

Re: Attaching a Resistor Between Two Stainless Rods

06/30/2009 11:01 PM

I think a lug is your answer. Something similar to:

http://www.alibaba.com/product-gs/222530205/ASL_Aluminium_Screw_Lug.html
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elnav
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#5
In reply to #4

Re: Attaching a Resistor Between Two Stainless Rods

07/01/2009 2:09 AM

Perhaps the poster can define the problem in better detail. Does it have to be an "H' physical shape such as in an antenna or does it just have to be electrical.

Using aluminum lugs on stainless steel is not recommended since galvanic action will cause corrosion that will interfe with any electrical action. Can the resistor be self supporting or does it require mechnaical support to prevent breakage of the wire leads?

If the stainless steel rods are further apart than the lenght of the resistor body you could drill a hole in each and then cross drill plus tap another hole to form a clamping action. The tinned wire of the resistor will resist corrosion better than aluminum would.

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Nigh
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#6

Re: Attaching a Resistor Between Two Stainless Rods

07/01/2009 4:29 AM

We do a similar thing with dropper resistors by putting nickel tags on the resistor & spot welding the tags to the stainless. This is for a low power application & the whole thing is encapsulated after so it's protected against the elements and physical loads.

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W9GFX
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#7
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Re: Attaching a Resistor Between Two Stainless Rods

07/01/2009 7:17 AM

First of all, thanks to all who responded. The "H" configuration is physical. This is a commercial project so I can't be too specific. The whole assembly will be encapsulated afterwards so it must be reliable. I feel spot welding is the best approach but need to know more about that. Could I correspond personally with you? Must the resistor have nickel leads for spot welding? Thanks so very much!
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Nigh
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#8
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Re: Attaching a Resistor Between Two Stainless Rods

07/01/2009 7:33 AM

No, we use standard resistors, we solder to the nickel tape (about 2.5 x 0.25mm tape) then spot weld the tape to the stainless. Our spot weld machines are very small so not much current involved. I can look up makes/models if you need it.

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Electronic Wiz
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#9
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Re: Attaching a Resistor Between Two Stainless Rods

07/01/2009 9:53 AM

A lot depends on what resistor you intend to use, there are several different materials used including solder-coated copper, tinned copper, copper-nickel, alloy 180 and copper-steel for leaded resistors. Lugs on larger power resistors are often copper-weld. Basically, most resistor terminals, wire or lugs are usually designed to be soldered to and most are not directly compatible to stainless. Staking is a possibility or spot welding with an intermediary material such as nickel but it wholly depends on the termination material.

However, you need to give resistor details, such as I asked for which will not give away any important details. With what you have told us so far, none of us can give a clear answer as to what you should do. I have worked in the resistor industry for many years. There are too many lead types to give a specific answer for without detail. Without the proper terminations, you are inviting failure.
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W9GFX
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#10
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Re: Attaching a Resistor Between Two Stainless Rods

07/02/2009 8:22 AM

Thanks to all, especially Whiz & Nigh. I now have the information that I needed.
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Anonymous Poster (2); Electronic Wiz (2); elnav (1); Nigh (2); plancette (1); W9GFX (2)

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