This website uses cookies. Further information can be found in our privacy policy.

Novel Spot-Welding Electrode Caps
Long service lifetime, no sticking to the sheet metal

Drahtspirale und Elektrodenkappen

The electrodes (often called electrode caps, depending on the design) are the most highly stressed components in spot welding equipment. They are wearing parts that can be replaced quickly. However, they shouldn’t actually require replacing that often...

Spot welding is a resistance welding process in which metal sheets are joined together without filler metal or protective gas – merely by pressing two pincer-like electrodes against each other. Spot welding is frequently used in the production of car bodies. The endmost part of the electrodes – which come into direct contact with the sheet metal – usually appear as cap-like plugs, which is where the name electrode cap comes from. Major manufacturers of spot-welding equipment include Fronius, Dalex, Kuka, Nimak and Kemppi.

Electrode caps must have excellent electrical conductivity and, at the same time, be able to withstand the combined thermal and mechanical wear stresses of spot welding. They are usually made of electrobronzes – and particularly often of CuCr1Zr. With regard to the combination of properties mentioned, however, such materials merely serve as a compromise. These electrodes wear out quickly and have to be changed frequently.

A particularly unpleasant phenomenon is the sticking of the electrode caps to the sheet metal. This can really downtime losses to add up.

Non-stick electrodes with longer lifetimes

With a material from CEP Freiberg, the lifetime of the electrode cap can be significantly extended. CEP DISCUP® VOLT is a unique powder-metallurgical copper-based high-temperature material – an ODS copper produced by means of special processes. It combines excellent electrical conductivity with the best possible high-temperature wear resistance. Above all, however, CEP DISCUP® VOLT minimises the tendency of spot-welding electrodes to stick.

If you would like to order semi-finished products made of CEP DISCUP® VOLT or have questions about further processing into electrode caps according to your company standard, please send us a message.