Method for welding the two steel wires of the fiber sheath to the tail fiber

The most reliable method is thermal fusion welding using a professional fiber optic fusion splicer, which melts the fiber ends and bonds them securely while protecting the steel sheath.

Preparation Steps

1. Strip and Clean the Fiber Use a cable stripper to remove the outer jacket and coating of the fiber optic cable, exposing the steel wires of the sheath and the bare fiber core. Carefully clean the exposed fiber with alcohol and a dust-free cloth to remove contaminants, which ensures a high-quality weld and minimal signal loss .
2. Insert Fiber Protection Sleeve Before welding, slide a heat-shrinkable fiber protection sleeve over the fiber. This sleeve will later protect the splice point and the steel wire connection from mechanical stress .
3. Cut and Align Fibers Use a precision cleaver to cut the fiber ends straight and flat. Proper alignment is critical; the steel wires of the sheath should be positioned so that they are in contact with the tail fiber without tension or bending .

Welding Process

1. Use a Fusion Splicer Place the prepared fiber ends and steel wires into the V-groove of a professional fusion splicer. Close the covers gently to avoid damaging the fibers. The splicer generates an electric arc that melts the fiber ends and fuses them together, creating a continuous optical path .
2. Monitor the Arc Observe the fusion process for bubbles, uneven melting, or separation. Adjust the splicer parameters such as pre-discharge time, main discharge time, and arc intensity according to the fiber type and steel wire thickness .
3. Heat the Protection Sleeve After welding, slide the fiber protection sleeve over the splice point and place it in the splicer's heating zone. Heat until the sleeve shrinks and secures both the fiber and the steel wires, providing mechanical stability and protection against environmental stress .

Post-Welding Steps

• Cooling and Inspection Allow the splice to cool in a tray to prevent thermal damage. Inspect the weld under a microscope to ensure a smooth, mirror-like surface and proper alignment .
• Placement in Splice Tray Arrange the welded fiber and steel wires in a splice tray or box, ensuring no sharp bends or tension. Proper coiling prevents breakage and maintains signal integrity .

Notes and Best Practices

• Manual welding without a splicer is possible but results in lower quality and shorter lifespan of the connection .
• Always follow manufacturer-recommended parameters for the fusion splicer to avoid high attenuation or reflection losses .
• Ensure the steel wires are tightly fixed in the splice box before welding to prevent movement during the fusion process . By following these steps, the steel wires of the fiber sheath can be securely welded to the tail fiber, ensuring a durable, low-loss optical connection suitable for telecommunications or high-speed data networks.