How to Size a Thermocouple Wire

Thermocouple wires form when you melt wires of two different metals together in a flash welding process to form a junction. Due to the nature of the welding process, the junction diameter tends to vary, and is not the best way to specify the size of a thermocouple wire. Instead, you can use the diameters of the individual wire conductors when calculating various measurements of the thermocouple wire size.

Things You'll Need

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Instructions

    • 1

      Use AWG (American Wire Gauge) standards to specify the size of your wire. AWG rating, assuming that the component wires of the thermocouple wire are equal in diameter, relates to the diameter of each individual wire in a formulaic manner. Wire diameter, in inches, equals 0.005*(92^((36-AWG)/39)). Using this equation, you can calculate the wire gauge of your thermocouple wire, which both the electronic and electrical fields recognize.

    • 2

      Size the thermocouple wire, alternatively, by the diameter of the conductors. Each of the two conductors will be the same diameter. Check the manufacturer's specifications to determine what this diameter is, or use a tool such as a caliper to size the diameters of your conductors.

    • 3

      Size your thermocouple wire by the cross-sectional area of one of your conductor wires, using this formula: Area = 3.14*(radius^2).

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