This paper describes the development of a specialized laser system for welding fast response small bead thermocouples. Fast response thermocouple performance is predicated by a small mass thermocouple junction. Up until now thermocouple bead diameters have been on the order of three times the wire diameter and have subsequently suffered a slow response time. With the system described herein the bead diameter is kept to a nearly 1:1 relationship with the wire.

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