You're welcome!
Wanna thank ya @aldenf for the excellent synopsis and taking the time to validate many of these basic ideas I've tried to faithfully convey here on ECF. Some differences but there's no way I can get to these in one evening. And on others where i'd love to entertain a discussion.
One I'd wish to emphasize again...that all wire has intrinsic internal imbalances of strain. Kanthal as you note also exhibits substantial variation of surface structure and runout (diameter) imperfections. Plentiful, even within a short section of wire. Each and every one of these capable of intruding into our vape and reflected in the unavoidable variability we see in reports by vapers attempting to reproduce the same wind. Maybe just fine for a toaster or refractory oven but more than just subtle enough to make our vape different from one wind to the next.
So just to focus on this I'd say understanding adhesion is central to this. It is the discovery of this in trying to reproduce the micro, adapting tension with an industry standard pin vise, that revealed that there's more to "sticky" than just symmetry. How important? Wire first compresses (deflects) then when closest proximity is achieved (adhesion), yields to elongation. This very subtly acts to further flatten the compressed wire surface. You simply can't get wire closer for oxidation. And what ever defects may exist in the material surface have been minimized in practical terms. There may still remain gaps but so small as to likely require optics to see. If open inter-turn gaps can be seen, the wind has failed or wire has serious diameter issues. But in this optimized state of contact oxidation can easily fill these small gaps very efficiently. And yes, to answer your question quickly.
To gain familiarity with response time to initiate wire lighting (I gave minimal power specs earlier in the thread) we need to find/learn the mark. It varies with wire gauge and to some extent the device whether mech, variable and type of modulation. I prefer and have done well over a thousand builds with variables of all kinds. Mech's too on occasion but when a batt at no more than half-charge or less and very light pulses. The norm for me is to use a var dev. Then turn axis strain (skew, what's liberated by brushing) AND inconsistent turn strain are often revealed in the first pulse or two by hi-side resistance Ω-reads (as wind suddenly goes high temp). Once identified turns can be returned by brushing, etc. to the wound state of rest (equilibrium) before RIDGIDITY is burned into wire memory. If pulsing goes too swiftly or at high temp during these initial fires (mebe x1 if >V) you've locked in whatever gaps or skew may be present. It's poss to release the lock with raking but too much repeated force can get you worse than skew, no adhesion. The wind may perform, even go full micro and exhibit considerably thermal evenness yet operate at higher temp/res. I've vaped lots of winds like this. Tossed out countless more. No point.
Why is this important?
You have two winds. One where oxidation is practically uniform, the other where gaps remain or uneven often insufficient alumina layers are present. Which will likely go out of res (temp) to the high side in operation? The goal is to control that. That's the criteria an earlier poster cited as imperative. True that.
I'd suggest some research on breakdown voltage to those interested. But essentially it's the point at which insulation is defeated and current will breach material surfaces. What I (and others here) refer to as electron jump. Really interesting stuff and quite the foundation for much of our problems. One of the most fascinating and alarming observations I made early on working with clearo's was just how easily higher applied voltage would defeat even careful consistent torching oxidation (before I learned how conductive it was). You see I was arc'ing leads seriously on Protanks due to assembly wall proximity. I hesitate to publish here the rest of my findings on that. Suffice it to say I became convinced how seriously important alumina oxidation was to a stable and safe vape.
In fairness to the coiler folks regarding utility, it is easier to wind thicker gauges into more consistent closer proximity. You can compress/anneal a coil to a state similar to Russ' original torched micro at thicker gauges. For the casual user, this might be just the ticket. But I don't think folks at 24AWG spec winds for their daily, like me, are going to be big fans of the coiler though. I threw one in my kit nonetheless 'cause you never know.
So what does this reveal. The most important objective of strain winding is oxidation. Especially for starter winders who very badly need to see circuit stability they can just count on to work. The build has enough variables to keep us all busy.
The problem with repeated pulse annealing or oxidation is that with every high temp fire we begin to soften, weaken and potentially warp the very precise contact we've just wound. Precise tensioned alignment helps to mitigate that but it's insurance, not protection. It's heart surgery on that wire. You want to get in and get out quick. Which means arriving at the minimal doorstep of adhesion, knockin' on it and making sure you've gained entry. That point to my present thinking is just as wire begins to fire end to end at the target color temperature which I posted on earlier.
Hopefully these points will help guide an approach to looking at this technique. Practice is perfect.
I truly hope the convo flourishes on all alternatives and sheds even more light on how to best complete the circuit. But adequate uniform oxidation is the essential ingredient missing from the vape.
Good luck all.
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