Abstract: Objective The aim is to realize reliable connection of 30 μm nickel alloy enameled wire in thermal flow sensors. Methods The feasibility of welding nickel alloy enameled wire by micro-resistance spot welding process with enamel removal is studied. The key factors affecting the micro-resistance spot welding of nickel alloy enameled wire are analyzed. The welding process parameters, microstructure and properties of soldered joints are experimentally analyied, and the welding quality and enamel removal are evaluated. Results The results show that the pure nickel pad material has high surface hardness, low resistivity and low thermal conductivity, which is suitable for the spot welding of nickel alloy enameled wire. With the soldered joint strength as the target, through the systematic analysis and experiments of welding pressure, welding voltage and welding time, joints with reliable mechanical properties can be obtained, and the enamel of enameled wire can be effectively removed. Conclusion The micro-resistance spot welding process with enamel removal is an effective means to achieve reliable connection of 30 μm nickel alloy enameled wire.