| Type: | Alloy Electrode |
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| Cooling System: | Nature Cooling |
| Function: | Plasma Generated Body |
| Materials: | Copper and Tungsten |
| Apply in: | Welding Equipment Industry |
| Making Method: | Back-Casting |
| Samples: |
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| Customization: |
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Supply of resistance welding electrodes, copper inlaid various non-ferrous metal electrodes
1. Introduction to resistance welding
Resistance welding refers to the method of using the resistance heat generated by current passing through the weldment and the contact point as a heat source to locally heat the weldment and pressurize the welding at the same time.
Resistance welding is a method that uses the resistance heating effect generated by the current flowing through the contact surface and adjacent areas of the workpiece to heat it to a molten or plastic state to form a metal bond.
There are four main resistance welding methods, namely spot welding, seam welding, projection welding, and butt welding. Among these four methods, resistance welding electrodes are required. Our company specializes in the production of resistance welding electrodes, from powder to tungsten and molybdenum products, tungsten-copper combination to precision-machined products, all are produced by our company. With many years of experience in the production and supply of welding electrodes, we have rich experience in how to improve product performance and life.
1). Spot welding: It is a high-speed and economical welding method, suitable for spot welding of carbon steel plates and stainless steel plates, high-carbon steel saw blades, iron wire products, wire terminals, auto parts, stainless steel products, low-voltage electrical appliances, and hardware Lighting, kitchen utensils, small household appliances, small hardware and other industries.
The materials used for spot welding include chromium zirconium copper, alumina copper and beryllium copper, etc. Our company has precision processing capabilities and can process them according to the drawings.
In addition, the copper-inlaid tungsten and copper-inlaid molybdenum electrodes produced by our company have remarkable welding performance and solder joints when welding copper wires, copper braided wires, copper sheets, copper tabs, carbon brush holders, gold wires, copper wires, aluminum foil, etc. Small, high consistency, long welding times and long life.
2). Seam welding: Seam welding is an extension of spot welding. It presses the weldment through a roller electrode and continuously rotates to send power to form a continuous weld. Our company produces seam welding electrodes, and the materials include molybdenum alloy and tungsten alloy. In addition, our company also produces parallel sealing and welding electrode wheels. These electrodes are also called capping electrodes and tungsten copper sealing and welding electrodes. They are mainly used in equipment for welding packaging devices, optical devices, sensor devices, and micro-electromechanical system devices.
3). Projection welding: Projection welding is also a form of spot welding. It uses the original profile, chamfer, and prefabricated bumps on the part to weld it to another larger part. In addition to projection welding of plates, projection welding also includes projection welding of nuts and screws, cross projection welding of wires, projection welding of pipes, and T-shaped projection welding of plates.
In terms of nut projection welding, tungsten copper nut electrodes are usually required. Our company can provide a variety of end faces such as pure tungsten, pure molybdenum, tungsten copper, etc. The base material is chromium zirconium copper. Made by back casting, the material life is much longer than that of the chromium zirconium copper nut electrode cover. Our company provides nut electrodes of different specifications. We can provide directly back-cast tungsten-copper nut electrodes through drawings, or we can provide tungsten-molybdenum wafers or tungsten-copper wafers for customers to use for brazing.
2. Definition, performance and characteristics of resistance welding electrodes
The resistance welding electrode is a component of the resistance welding machine that directly contacts the weldment and transmits current to the weldment. It has an important impact on the welding quality and efficiency.
Resistance welding electrodes are usually made of metal materials with good electrical conductivity, such as copper, chromium zirconium copper, and tungsten copper. Its shape and size will be designed and manufactured according to the specific welding process and weldment requirements.
During the resistance welding process, the electrode generates resistance heat through contact with the surface of the weldment, causing the weldment to be locally heated to a molten or plastic state, thereby achieving welding. In order to ensure welding quality, the electrode needs to have the following characteristics:
1). Good electrical conductivity: ensure that current can pass through the electrode evenly to produce a uniform heating effect.
2). Appropriate hardness and wear resistance: It can withstand the pressure and friction during the welding process and extend the service life of the electrode.
3). High temperature resistance: maintain good performance at high temperatures and avoid deformation or melting.
4). Easy maintenance and replacement: It facilitates cleaning and trimming of electrodes to ensure the stability of welding quality.
In addition, the surface quality of the electrode will also affect the welding quality. The electrode surface should be smooth and flat without dirt, oxide layer or other impurities to ensure good contact with the weldment.
3. Selection of resistance welding electrode materials
Resistance welding is mainly used for welding metal materials. For different metals, different electrode materials are used.
Tungsten (W)
1). More than 99.95% of general ingredients
2). It has the highest melting point among metals (3410°C)
3). High hardness at room temperature and high temperature
4). Sensitive to mechanical and thermal shock and cracking
5). Low reactivity with other metal components
6). High resistance
Tungsten properties
| Composition (%wt.) | Density (g/cm3) | Hardness (HRC) | Conductivity (%IACS) | Class | RWMA | Advantages |
| Tungsten content ≥99.95 | 19.3 | 36 | 30 | 13 | 13.743 | High temperature resistance |
| Cerium tungsten (CeO2:2%) | 19.2 | - | - | - | - | Low discharge power, good arc starting performance, excellent arc ablation resistance, and longer service life |
| Lanthanum tungsten (La2O3: 1-2%) | 19.2 | - | - | - | - | Low discharge power, easy to process |
Molybdenum (Mo)
More than 99.95% of general ingredients
1. High melting point (2623°C)
2. Better resistance to mechanical and thermal shock than tungsten
3. Lower hardness at room temperature and high temperature compared to tungsten
4. Low reactivity with other metal components
5. Electrical and thermal properties are comparable to tungsten
Molybdenum alloyTZM alloy
An alloy made of titanium, zirconium, and molybdenum (0.5% Ti, 0.08% Zr, and 99.4% Mo).
1. High melting point
2. Good chemical resistance
3. Higher hardness than pure molybdenum
4. Good thermal conductivity and electrical resistance
MoLa alloy
Molybdenum-lanthanum alloy (MoLa), also known as high-temperature molybdenum, is a molybdenum alloy that is doped with rare earth lanthanum elements to improve the high-temperature performance and other properties of molybdenum.
1. High melting point
2. Enhanced creep resistance
3. Compared with pure molybdenum, the high temperature resistance is improved
4. Better electron emission performance
Molybdenum properties
| Composition (%wt.) | Density (g/cm3) | Hardness (HRB) | Conductivity (%IACS) | RWMA | Advantages |
| Molybdenum content ≥99.95 | 10.2 | 90 | 30 | 14.423 | Excellent electrical and thermal conductivity |
| Titanium Zirconium Molybdenum Alloy TZM (Ti: 0.5%, Zr: 0.08%, C: 0.02%) | 10.17 | High heat resistance and creep resistance | |||
| Molybdenum lanthanum alloy Mola (La2O3: 0.1 -1.8%) | 10.19 | High heat resistance and creep resistance |
Copper tungsten (CuW)
An alloy made of copper and tungsten.
1. Its performance is between copper alloy and tungsten
2. Moderate hardness at high temperatures
3. Better conductivity than tungsten and molybdenum
Tungsten copper material properties
| Product name Copper | Copper content % | Density g/cm3 ≥ | Conductivity IACS %≥ | Hardness HB Kgf/mm2 ≥ |
| 50 tungsten copper | 50±2.0 | 11.85 | 54 | 115 |
| 55 tungsten copper | 45±2.0 | 12.3 | 49 | 125 |
| 60 tungsten copper | 40±2.0 | 12.75 | 47 | 140 |
| 65 tungsten copper | 35±2.0 | 13.3 | 44 | 155 |
| 70 tungsten copper | 30±2.0 | 13.8 | 42 | 175 |
| 75 tungsten copper | 25±2.0 | 14.5 | 38 | 195 |
| 80 tungsten copper | 20±2.0 | 15.15 | 34 | 220 |
| 85 tungsten copper | 15±2.0 | 15.9 | 30 | 240 |
| 90 tungsten copper | 10±2.0 | 16.75 | 27 | 260 |
Silver Tungsten Alloy (AgW)
An alloy made of silver and tungsten.
1. Like copper-tungsten alloy, silver-tungsten is characterized by medium hardness and conductivity at high temperatures
2. For welding stainless steel and/or nickel foil
| Product name | Content (%wt.) | Density (g/cm³) ≥ | Hardness(HRB) ≥ | Conductivity(%IACS) ≥ |
| Silver Tungsten 65 | Tungsten:65%, balance silver | 14.5 | 75 | 48 |
| Silver Tungsten 70 | Tungsten:70%, balance silver | 14.9 | 82 | 45 |
| Silver Tungsten 75 | Tungsten:75%, balance silver | 15.4 | 86 | 41 |
Good spot welding quality can only be ensured by matching materials. There are also many kinds of electrode shapes, and the commonly used ones are R type, P type, F type and CF type.
4. The characteristics of different electrode materials are shown in the table below:
Electrode material Main components Characteristics Materials suitable for welding
Chrome copper Cu-Cr precipitation hardening alloy has high thermal and electrical conductivity and is a more economical choice. Soft steel, steel sheets
Chromium Zirconium Copper Cu-Cr-Zr precipitation hardening alloy has high heating resistance and higher hardness than chromium copper. Soft steel, steel sheets
Alumina-strengthened dispersed copper Cu-Al2O3 dispersion hardened alloy is softer than chromium copper, but will not deform after high temperatures. Surface treated steel and steel sheets
Tungsten W is a high melting point material with high heating resistance and low thermal and electrical conductivity. copper
Molybdenum Mo has poorer wear resistance than tungsten, but is more economical, more workable, and easier to process. copper
Tungsten copper Cu-W is between tungsten and chromium copper in terms of thermal and electrical conductivity. It is not easy to bend and is easy to process. Depends on electrode
Silver tungsten Ag-W is similar to tungsten copper in terms of thermal and electrical conductivity, and is used in situations where copper alloy cannot be used. Depends on electrode
Our company has many years of service experience in the field of resistance welding, and electrode materials and electrode finished products are sold to domestic and foreign customers. Based on our rich production experience and service experience, we continue to develop new products and improve material properties, and our products are widely praised by customers.
Here are some product examples:
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https://weilainewmaterials.en.made-in-china.com/product-list-1.html
Zhuzhou Weilai New Materials Technology Co., Ltd (Weilai) is located in China Power Valley in Zhuzhou City of Hunan province. Weilai devotes to research and develop high performance heterogeneous refractory metal composites, including high-performance X-ray tube anode material, plasma spray nozzle as well as the electrodes and the resistance welding electrodes, etc. It is mainly used in medical equipment, plasma spray and automobile electrical equipment industries. Weilai provides the customized solutions for customers, it is a high-tech company integrating research and development, production, sales and service.
Adhering to "Keep improving products and creating value for customers", the company focuses on the subdivided fields of refractory metal materials industry, continuously optimizes the technological adaptability of products, develops more supporting products in the industry, and provides users with more reasonable and comprehensive solutions. Weilai makes constant efforts to "become an excellent company in the field of new materials".
Advantages of plasma spray nozzles and electrodes,resistance welding electrodes and stationary anode targets:
1. Our company has been engaged in the production of pure tungsten and tungsten alloy materials for many years, and has an in-depth understanding of the structure and properties of materials. For the tungsten electrode used in plasma spraying electrodes, based on our full understanding of the application, we have made more improvements and treatments to the material structure to meet the material requirements of plasma spraying. By densifying the tungsten electrode, a finer, more uniform grain structure is formed. The modified tungsten alloy has relatively high hardness and density, fast arc starting, excellent resistance to arc burning loss, and long life.
2. Our company's plasma spraying electrodes and nozzles use unique back-casting technology to achieve seamless bonding between tungsten and copper. The bonding strength can be as high as 127MPa, while the traditional bonding strength is less than 100MPa. Compared with traditional brazing, joints made by back-casting have higher bonding strength between tungsten and copper, larger contact area, more uniform resistance, and stronger heat dissipation ability, making the nozzle and electrode more stable and more durable as well as long service life.
3. We produce tungsten electrodes of different materials (good arc starting performance and ablation resistance). Based on customer usage conditions, we can provide more suitable materials for customers to choose.
| Material | Impurity content (%) | Electron work function (eV) |
| Lanthanum tungsten | <0.2 | 2.8-3.2 |
| Cerium tungsten | <0.2 | 2.7-2.8 |
| Thorium tungsten | <0.2 | 2.0-3.9 |
4. Based on the research and analysis of plasma spray guns, the electrodes and nozzles produced by our company can perfectly adapt to the original spray guns, and no additional adjustment of spraying parameters is required during replacement. We have a complete product series, and the plasma spray electrodes and nozzles we produce can be widely used in F4, 9M, SG-100 and other spray guns of Metco, GTV, FST, AMT AG, Praxair and other companies.
5. We have rich experience in producing various cathodes and anodes, which can be customized and processed according to customer samples or drawings. We can also provide semi-finished products with seamless combination of tungsten and copper.
We can ensure our all products which are seamless bonding,no gas foam generating,and assure concentricity,if any defect has been found which are due to our cause,we can replace them for free and send you along with shipment for next time.
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