System And Method For Improved Resistance Welding Electrode Life

A method for performing a resistance welding process between a metal actuator and a shape memory alloy (SMA) wire, the method comprising:

• positioning a resistance welder at a first end of the SMA wire and the metal actuator such that a top electrode is disposed adjacent to the SMA wire and a second electrode of the resistance welder is disposed adjacent to the metal actuator, wherein an electrode material is a tungsten alloy that includes an increased resistance to a resistance of tungsten copper;
• performing, by the resistance welder, a first resistance weld at the first end of the SMA wire and the metal actuator by passing a current through the SMA wire and the metal actuator;
• positioning the resistance welder at a second end of the SMA wire and the metal actuator such that the top electrode is disposed adjacent to the second end of the SMA wire and the second electrode of the resistance welder is disposed adjacent to the second end of the metal actuator;
• and
• performing, by the resistance welder, a second resistance weld at the second end of the SMA wire and the metal actuator by passing the current through the SMA wire and the metal actuator, wherein each of the first and second resistance welds are performed for a weld pulse duration of around 9 milliseconds (ms).