Resistance welding electrode cap
AssigneeSCM Corporation
InventorsAnil V. Nadkarni, Prasanna K. Samal
Life of this patent
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Abstract
An improved resistance welding electrode cap adapted to being internally cooled with a flow of coolant has a main body portion with a nose root at one end and an electrical and coolant connection projecting from the other, the area of the root being substantially smaller than that of the direct projection of the main body portion, a pronounced nose projecting from the root. The whole nose is of dispersion-strengthened copper, as is at least the main body portion. Such cap provides astonishingly improved performance for resistance welding, even of galvanized steel, and particularly of double-sided, galvanized cold-rolled steel sheet.
Claims13
A cold formed or machined unitary resistance welding electrode cap formed of dispersion strengthened copper and adapted to be internally cooled with a flow of coolant, said cap having a main body portion including an inner recess for coolant at its proximal end and an elongated nose portion terminating in an integral welding tip face at its distal end and an intermediate root portion connecting the nose portion and the main body portion, and wherein said nose is slightly tapered, is at least about 5 mm long from root to tip, has horizontal cross sectional area of tip not substantially in excess of about 4/10ths that of said main body portion at its greatest extent, has nose length to nose tip width ratio not substantially in excess of about 2, and is entirely of dispersion-strengthened copper except for optional jacketing of at least part of the main body portion with another metal.
A process for welding steel surfaces together, at least one of which steel surfaces includes a zinc-coating, which comprises contacting opposite sides of the weld joint with resistance welding electrodes and passing an electric current therethrough of sufficient density to weld the surfaces together, the electrode or electrodes in contact with a zinc coated surface or surfaces including a cold formed or machined unitary resistance welding electrode cap formed of dispersion strengthened copper containing between about 0.25% and about 0.6% alumina by weight measured as equivalent aluminum, cooling said electrode cap internally with a flow of coolant, said electrode cap having a main body portion including an inner recess for receiving coolant at its proximal end, and a nose portion terminating in an integral welding tip face at its distal end, and an intermediate root portion disposed between the nose portion and the main body portion, and wherein said nose is slightly tapered, is at least about 5 mm long from root to tip, has horizontal cross sectional area of tip not substantially in excess of about 4/10ths that of said main body portion at its greatest extent, has nose length to nose tip width ratio not substantially in excess of about 2, and is entirely of dispersion-strengthened copper except for optional jacketing of at least part of the main body portion with another metal.
A process for welding steel surfaces together, at least one of which steel surfaces includes a zinc-coating, which comprises contacting opposite sides of the weld joint with resistance welding electrodes and passing an electric current therethrough of sufficient density to weld the surfaces together, the electrode or electrodes in contact with a zinc coated surface or surfaces including a cold formed or machined unitary resistance welding electrode cap formed for dispersion strengthened copper cooling said electrode cap internally with a flow of coolant, said electrode cap having a main body portion including an inner recess for receiving coolant at its proximal end, and a nose portion terminating in an integral welding tip face at its distal end, and an intermediate root portion disposed between the nose portion and the main body portion, and wherein said nose is slightly tapered, is at least about 5 mm long from root to tip, has horizontal cross sectional area of tip not substantially in excess of about 4/10ths that of said main body portion at its greatest extent, has nose length to nose tip width ratio not substantially in excess of about 2, and is entirely of dispersion-strengthened copper except for optional jacketing of at least part of the main body poriton with another metal.
Dependencies are inferred from the claim text.