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Abbott Vascular encountered strength and variability issues when attempting to resistively weld 304 Stainless Steel to equiatomic Nitinol. Initial observations suggested that passivation layer (Cr 2 O 3 , TiO 2) formation affected the weld interface. One hundred 304 Stainless Steel/Nitinol pairs were allowed to oxidize in air at room temperature for allowed periods of time hours). Each pair was welded resistively with constant current. A Miyachi/Unitek Advanced Data Analysis Monitor (ADAM) recorded the peak resistance at the instance the weld was made. Resistances were compared to Instron 5900 tensile maximum break load (KgF). Use of optical microscopy and Scanning Electron Microscopy (SEM) revealed microstructural reduction of void size at the sample fracture surface (1-.5 µm). Literature suggested the existence of metastable precipitate forms at near equiatomic compositions within the theoretical temperature range (261.9-1425.2 0 C). The Instron 5900 mechanically validated presence of precipitates, while Electron Dispersive X-Ray Spectroscopy (EDS) confirmed the existence compositionally. Literature confirms B19' precipitates size increases with temperature. This suggests higher resistance samples will promote growth of precipitates due to increased heat input. Increased average particle size was observed with increased resistance (0-.3 µm). Crystal lattice inconsistencies between Nitinol parent phase (B2) and B19' promote premature fracture due to increased misfit dislocation density. Therefore increased weld resistance promotes the growth of incoherent Ti 3 Ni 4 precipitates which inhibit load bearing capabilities, causing premature failure.

Effect of Oxidation on Weld Strengthof Dissimilar Resistance Weld Interface Between 304 Stainless Steeland Near Equiatomic Austenitic Nitinol Guide Wire