TUFFALOY
helpful suggestions
Many factors affecting electrode cost and useful electrode life
are briefly outlined below.
The RWMA tip numbering system has generally replaced the
old Morse taper numbers with new “RW” numbers, and has
added two new sizes, as the chart illustrates.
PART TO BE WELDED
Lay out the part for resistance welding. Designing engineer,
welding engineer and production man in charge of welding
should cooperate in securing a better product at lowest cost.
Correct design permits the use of standard straight electrodes:
or standard offset or standard angular holders if the straight
approach is not possible. Special shaped electrodes cost
more, and the difficulty of cooling the electrode is amplified.
Single spot, multiple spot, projection, or other method may
be accurately chosen to achieve lowest cost. Consult the
R.W.M.A Manual.*
MATERIAL TO BE WELDED
The weldability of the materials can be determined by consulting
your material supplier, and by reviewing recommendations
covered in the R.W.M.A Manual.*
Surface conditions, rust, oil, dirt, and, on many articles, oxide film
and even handling marks have a decided effect on weld quality.
Cleaning may have to be a part of the welding job in some cases.
ELECTRODE LIFE SAVERS
1. Use standard Tuffaloy electrodes with Tuffaloy
ejector type, self-adjusting tube, water-cooled
electrode holders wherever possible. Avoid
special or irregular shapes for lowest cost.
WELDING EQUIPMENT AND CONTROL
A welding machine of reputable quality purchased for a
particular application will be correctly designed both electrically
and mechanically, and will be supplied the correct control
equipment and electrodes for the work.
2. Use ample cold cooling water as close as practical
to the welding contact surface, properly circulated
at a minimum of 30-psi pressure, and supplied at a
rate of at least 1-1/2 gallons per minute.
On machine change-overs make sure of adequate electrical
and mechanical capacity, and see that the necessary controls
are provided. Consult us when redesigning or revising your
choice of electrodes.
3. Be sure to select the proper type and size of
electrode, taking into consideration electrode
pressure, contact area of electrode, gauge, and
nature of material to be welded. Consult the RWMA
Manual* or your Tuffaloy field engineer regarding
recommended practices. Overloading as well as
overheating shortens electrode life.
STANDARD GAGE CHART
Thickness in Decimals of an Inch
Gage Manufacturer’s Gage Manufacturer’s Gage Manufacturer’s
No.
Standard
No.
Standard
No.
Standard
3
4
5
6
7
8
9
10
11
0.2391
0.2242
0.2092
0.1943
0.1793
0.1644
0.1495
0.1345
0.1196
12
13
14
15
16
17
18
19
20
21
0.1046
0.0897
0.0747
0.0673
0.0598
0,0538
0.0478
0.0418
0.0359
0.0329
22
23
24
25
26
27
28
29
30
0.0299
0.0269
0.0239
0.0209
0.0179
0.0164
0.0149
0.0135
0.0120
4. Good welds depend upon properly maintained
electrodes which assure an accurate surface
contact. Keep tapers clean and dress electrode
faces with lathe, emery paddle or fine file.
Use castor oil or graphite grease to facilitate
tip removal, and avoid application of insulators
such as teflon tape and other materials.
* Resistance Welding Manual, published by the Resistance Welder
Manufacturers Association.
RESISTANCE WELDING MACHINE SETUP
TO DETERMINE SPOT WELDING SCHEDULE
APPROXIMATE PRESSURE EXERTED BY AIR CYLINDER SIZE
DIAMETER CYLINDER AREA
SQ. INCHES
CURRENT
TIME
=
=
=
2T x 100,000
2T x 100
=
=
=
AMPERES
CYCLES
4”
5”
6”
8”
=
=
=
=
12.5
19.5
28.0
50.0
x
x
x
x
=
=
=
=
WELDER
GUAGE
PRESSURE
ELECTRODE
FORCE
PRESSURE
PRESSURE
2T x 6000 (LB)
FORCE REQUIRED (LB)
T = THICKNESS OF THE THINNEST PIECE
50
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