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I have a miniature two wire PT100 and need to extend its leads. Given the temperature at which it may operate, I cannot solder extensions. Is welding an option, and if so how do I go about it?

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  • \$\begingroup\$ Why not crimp ? \$\endgroup\$ – Wesley Lee Dec 1 '16 at 15:37
  • \$\begingroup\$ @WesleyLee Maybe, but it is quite fine wire and will be exposed to extremes of temperature \$\endgroup\$ – Dirk Bruere Dec 1 '16 at 15:42
  • \$\begingroup\$ What's the diameter of your wires? \$\endgroup\$ – Nick Alexeev Dec 1 '16 at 16:35
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    \$\begingroup\$ "Crimping" is exactly the same as "cold welding", if it is done with a proper crimping tool. \$\endgroup\$ – alephzero Dec 1 '16 at 19:37
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    \$\begingroup\$ What do you mean exactly by extreme temperatures? Can you disclose the temperature range you are planning to use that PTC for? \$\endgroup\$ – Lorenzo Donati Dec 1 '16 at 19:41
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Sure, welding is a good option.

We use a Japanese machine that produces very repeatable welds of fine wire and exotic materials. I think it cost less than $10K USD including the head.

You could also consider brazing the leads with silver solder, which requires little equipment.

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I'd suggest using RTD Connectors: http://www.omega.com/pptst/OTP.html
This supports the wire and outer sheath properly.

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