The HotSpot tools are portable, capacitive, discharge welding units that enable thermocouple wires to be transformed into freestanding beads or directly welded to metal surfaces for temperature sensing. Direct bonding avoids the need for clamps, brackets, straps, and welded wells, and provides a simple, low-cost means of attaching thermocouple sensing wires. The HotSpots are equally effective in forming freestanding beads or butt-welded thermocouple junctions. It takes only seconds to form standard thermocouple wire into a variety of attached or unattached sensors.

Thermocouples can be formed directly from standard wire types as either freestanding or surface-mounted junctions. Installation does not require skilled operators or prepared surfaces. Installation and material costs are low, allowing redundant junctions to be provided without incurring significant additional costs.

A welded junction provides an accurate thermocouple having a high-speed response characteristic. Beads can be made to desired size. A front panel power control on the HotSpot tool provides adjustment for handling various thermocouple wire sizes and materials, simplifying operator training and use. And a visual indicator alerts the operator when the unit has recycled following a weld, and a new cycle can be initiated. The instrument is well suited for shop, laboratory and pilot-run use.

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