Abstract: A method of making cathodes includes forming a first intermediate assembly having a current wire in juxtaposition with an outer mandrel wire and a basket wire wound around the first two wires. The first intermediate assembly is wound around a central mandrel to form a second intermediate assembly. Pulses of energy are used to produce an alloy solder joint between the current wire and the basket wire at selected locations. The second intermediate assembly is cut into segments, and the mandrels are removed. This results in a cathode having a coiled current wire and a basket wire wound around the current wire, with the basket wire being bonded to the current wire by the alloy solder joints. The cathode includes a central bore that is substantially free of the alloy solder joint.

Abstract: A spooling machine for winding wire, especially having a non-circular cross-section. A traverse mechanism reciprocates a wire guide or the spool relative to each other, the guide following a relative path such that at the end of a layer the guide clears the spool flange with a small clearance. Upon completion of one layer, the traverse proceeds in the new direction at a high rate of speed for a transition period corresponding to one-fourth to one-third lay, so as to place a relatively sharp bend in the wire where it climbs from the last turn of one layer to the first turn of the next.