This 14-karat yellow gold heavy bracelet chain has a broken tongue at its critical springy location (A). An ideal method for its repair is a non-torch pulse-arc welding approach so the alloy in the mechanism is not annealed or softened in the process.

For this repair, the ABI Tack II and Pulse-Arc welders provide the ideal solution.

Box Clasp Tongue Repair using Pulse-Arc-Welder Technology

First file or sand a smooth flat joint on both sides of the broken tongue. The joint should be prepared so the tongue will be angled properly for a secure fit in the box catch after the welding has been completed.
Tack-weld the broken tongue in place (B). The ABI tack welder was set at 40 volts and on the high-energy setting. Use the tweezers lead to hold the bracelet and the pliers lead to hold the tongue. Hold the parts with the leads using firm pressure.
Depress the foot pedal once to provide a single pulse of energy to complete the tack-weld. If the alignment is satisfactory, proceed to pulse-arc welding the joint.

NOTE: If you are not satisfied with the initial alignment, use moderate finger pressure to break the finding apart at the tack-weld joint. Re-sand the joint, position and re-tack.

For this volume and alloy of material, the ABI Pulse-Arc welder was set on 40 volts at the high-energy setting. Use the #2 welding tip on the welding pencil. The electrode of the welding pencil is recessed about one millimeter inside the ceramic tip. Use repeated pulses of energy complete the pulse-arc welding across the joint.
After the welding procedure, inspect the joint to insure it is complete. Test the spring and security of the joint.
Use Foredom’s ceramic impregnated rubberized abrasive wheels to smooth the joint. They come in six different color coded grits measuring 7/8 inch diameter x 1/8 inch thick. The grits range from coarse (120 grit) to super fine (1500 grit). They generate less heat when used and last longer.
Polish, clean and prepare for customer delivery.
This repair process took 4 minutes to complete. The tongue did not become annealed or softened during the tack and pulse-arc welding process and did not require extensive pre-finishing, finishing and polishing.


All tack-, fusion- and pulse-arc equipment settings will differ and are based upon the volume, amount of contact and alloy of the material you are assembling. Working with like materials will give you a parameter for the settings required for your application. Keep a record of settings and tasks for future reference.

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For questions related to this process, contact Mark B. Mann at For general information related to ABI equipment and procedures, or for a list of distributors, contact Janet Kirk at 888-494-2663 .