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RESISTANCE WELDING

PRODUCTS


ELECTRODES  HOLDERS  BAR STOCK  SEAM WELDING WHEELS


 SPECIAL DIES  SHAFTS  BUSHINGS  CASTINGS
 FORGINGS  ELECTRODE MATERIALS

RINGS

Special electrodes, holders and dies for


resistance welding applications

Continuously serving the resistance Welding Industry since 1929, CMW Inc. is an industry leader in the development, engineering and manufacturing of a variety of products. In addition, CMW offers a diversity of special metals for resistance welding applications. CMWs resistance welding products are engineered to provide the most effective materials commercially
available to help achieve top quality welds. Experienced CMW engineers will aid you in the design and production of standard or special parts for your application to insure maximum efficiency from CMWs resistance welding products.

CMW Inc.
70 S. Gray Street
Indianapolis, IN 46201

Phone: 866-634-8884
Fax: 866-239-6995
Email: cmw@cmwinc.com
Website: www.cmwinc.com

 CMW INC. 1990, 1993, 1999, 2001, 2002, 2004, 2005, 2007

CMW Inc.
P.O. Box 2266
Indianapolis, IN 46206

RESISTANCE WELDING PRODUCTS


Phone: 866-634-8884

Fax: 866-239-6995

Email: cmw@cmwinc.com

MALE THREADED BUTTON ELECTRODES

www.cmwinc.com

RESISTANCE WELDING PRODUCTS


Phone: 866-634-8884

Fax: 866-239-6995

Email: cmw@cmwinc.com

www.cmwinc.com

COPPER BASE ALLOYS


Phone: 866-634-8884

Fax: 866-239-6995

Long electrode life is of paramount importance to the user


of resistance welding equipment. Selection of the proper
CMW alloy or combination of alloys will help to give
improved weld strength and electrode life.

Email: cmw@cmwinc.com

CMW electrodes are fabricated from alloys selected from


the results of laboratory and practical field tests. For special
problems, CMW engineers will make recommendations
based on their years of experience.

Typical Physical and Mechanical Properties of CMW Copper Based Alloys


CMW
ALLOY
CMW 28
CMW 3
CMW 328
CMW 353
CMW 100

Condition
Wrought**
Cast
Wrought***
Wrought***
Wrought
Cast

Copper

Wrought
Cast
Wrought
Cast
Cast
Wrought

ELKALOY20

Wrought

CMW 73
ELKALOY D

Principal Elements

Class #

R.W.M.A.
Alloy
Number

Electrical
Conductivity
%I.A.C.S.

Ultimate
Tensile
Strength, psi

Elongation
% in 2"

70 B
70 B
83 B

90
80
85

66,000
50,000
75,000

10
20
15

500
500
500

930
930
930

83 B
94 B
90 B

85
48
48

75,000
100,000
85,000

15
13
10

500
455
455

930
850
850

100 B
38 C
38 C
92 B
30 B
40 B

48
20
23
13
95
100

110,000
110,000
170,000
85,000
25,000
40,000

10
2
4
15
50
35

455
375
375
620
200
200

850
710
710
1150
390
390

75 B

85

54,000

25

800

1475

Copper, Zirconium

1.15000

Copper, Chromium
Copper, Chromium,
Zirconium
Copper, Nickel,
Silicon, Chromium
Copper, Nickel,
Beryllium

2.18200

2.18150

3.18000

3.17510

Copper, Beryllium
Copper, Aluminum

4
5

4.17200
5.95300

Pure Copper
Copper, Al2O3

20

Hardness
Rockwell

Permanent Softening
Begins at
o
o
C
F

Note: All properties shown are TYPICAL and should not be used for specifications
** Cold drawn bars up to 5/8" diameter
*** Heat treated and cold drawn bars up to 1" diameter

TYPICAL USAGE
CMW 28 material is recommended for spot welding
of coated steels and high conductivity materials, excluding
copper and silver.
CMW 3 material is recommended for spot and seam
welding cold and hot-rolled steels and coated materials as
well as current carrying shafts and arms, back-up bars for
both resistance and arc welding and electrical current carrying structural parts and springs.

CMW 100 material is recommended for spot and seam


welding stainless steel and high temperature heat resisting
alloys requiring high weld forces, flash welding dies, back-up
bars, projection welding electrodes, and high strength, high
conductivity electrical components and springs.
CMW 73 material is recommended for flash welding
dies, springs, electrical components, high strength backing
material for brazed assemblies and wire guides.

CMW 328 material is recommended for spot and


seam welding cold and hot rolled steels. There is some
evidence that CMW 328 outperforms CMW 3 material
when welding coated or galvanized steels.

ELKALOY D material is recommended for butt and


flash welding dies and clamps for cold rolled and stainless
steel, current carrying structural parts, jigs and fixtures, pickling racks and baskets.

CMW 353 material is recommended for heavy duty


offset holders, back-up bars, flash welding dies, current
carrying structural members, shafts and bushings in combination with CMW 3.

ELKALOY 20 material has exceptional resistance to


deformation when welding, and is highly recommended for
welding caps for welding coated and galvanized steels. It
allows a stable start-up, and generally outlasts other cap
materials when welding parameters are not carefully controlled. The material requires upset cold work to develop its
properties, and is therefore only available as caps or cap
blanks.

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ELKONITE, ELKON, AND ANVILOY MATERIAL


Phone: 866-634-8884

Fax: 866-239-6995

ELKONITE is the registered trade mark of CMW used


to identify a group of metal compositions whose elements
consist basically of the refractory metals tungsten, molybdenum and tungsten carbide combined with copper.
Combinations of these elements produce dense, hard metals of superior wear resistance and strength at elevated
temperatures, coupled with good thermal and electrical
conductivity. The mechanical and physical properties of the
ELKONITE materials make them particularly suitable as
the die inserts and facings for volume projection welding,

Email: cmw@cmwinc.com
flash and butt welding, electrical upsetting, electroforging
and mash welding applications.
ELKONITE material is also used successfully as facing
on spot welding electrodes where heat balance or mechanical wear resistance are required. The initial premium cost of
ELKONITE material is offset by lower production cost per
weld due to long die life and less electrode dressing time.
The high stability of ELKONITE material insures uniform
heating and prevents misalignment, resulting in a higher
quality weld.

Typical Physical and Mechanical Properties of CMW Refractory Based Materials


CMW
GRADE
ELKONITE 1W3
ELKONITE 3W3
ELKONITE 5W3
ELKONITE 10W3
ELKONITE 30W3
ELKONITE 3W53
ELKONITE 10W53*
ELKONITE TC5
ELKONITE TC10
ELKONITE TC20
ELKONITE TC53*
ELKON 100W
ELKON 100M
ANVILOY 1150**

Type of Material
Tungsten-Copper
Tungsten-Copper
Tungsten-Copper
Tungsten-Copper
Tungsten-Copper
Tungsten-Copper Alloy
Tungsten-Copper Alloy
Tungsten Carbide-Copper
Tungsten Carbide-Copper
Tungsten Carbide-Copper
Tungsten Carbide-Copper Alloy
Tungsten
Molybdenum
Tungsten-Nickel-Iron-Molybdenum

Class #
10

11
12

13
14

R.W.M.A.
Group B
Material
10.74450

11.74400
12.74350

13.74300
14.42300

Hardness
Rockwell
77 B
90 B
95 B
98 B
103 B
105 B
109 B
94 B
100 B
37 C
47 C
39 C
90 B
34 C

Electrical
Conductivity
%I.A.C.S.
53
50
48
45
41
30
28
45
42
30
18
30
30
13

Ultimate
Tensile
Strength, psi
63,000
75,000
85,000
90,000
98,000
120,000
160,000
70,000
75,000
85,000
150,000
150,000
80,000
140,000

Cross Breaking
Strength
psi
110,000
130,000
140,000
150,000
170,000
180,000
200,000
140,000
160,000
180,000
220,000
200,000
120,000
280,000

Note: All properties shown are TYPICAL and should not be used for specifications
* Properties are in fully heat treated condition
** Hardness is 56 HRA at 1475 oF (800oC)

TYPICAL USES
ELKONITE 1W3 and 3W3 alloys are generally used for
flash and butt welding die inserts where higher electrical and thermal conductivity is necessary and where a degree of malleability
is desirable. These materials are also used for spot welding (as a
radius faced electrode) low conductivity ferrous metals such as
stainless steel.
ELKONITE 5W3 and TC5 alloys are normally used for light
duty projection welding dies where welding pressures are not
extreme.
ELKONITE 10W3 alloy is used for electrode and die inserts
in most flash and butt welding dies and for projection welding dies
where welding pressures are moderate. It is also used for light
electrical upsetting, electroforging dies and seam welder bushing
inserts.
ELKONITE 30W3 and TC10 alloys are recommended for
volume projection welding dies where the pressures involved are
relatively high. Electrical upsetting of non-ferrous metals and low
carbon steel is usually accomplished by the use of such
ELKONITE materials as die facings. Cross-wire welding of large,
diameter wire and rod is accomplished with such ELKONITE
materials.
ELKONITE 3W53 and 10W53 are heat treatable grades of
ELKONITE materials supplied in the fully heat treated condition.
If silver brazed to a die backing, such ELKONITE materials
should be heat treated after brazing. These harder grades are
used primarily for electroforging and electrical upsetting dies,
where temperatures and pressures are comparatively high.
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ELKONITE TC20 and TC53 materials are extremely hard


and wear resistant. ELKONITE TC20 material, while somewhat
difficult to machine, may be machined using carbide tipped tools.
ELKONITE TC53 material is a heat treatable grade of such high
hardness that machining operations are impractical and the material must be ground. Such ELKONITE materials are customarily
used for special applications of electrical upsetting and electroforging.
ELKON 100W is extremely hard and its ductility is relatively low. It cannot be machined but may be ground to the required
shape. It does not alloy appreciably with nonferrous materials and
is used for cross-wire welding of metals such as copper and
brass. It is also used for electrobrazing electrode material and for
some electrical upsetting operations.
ELKON 100M is used principally for electrobrazing electrode material and for cross-wire welding of nonferrous metals. It
is not as hard as ELKON 100W material and may be machined
or drilled to fit the parts to be joined. A typical application of this
material, as an electrode, is the welding or brazing of braided or
solid copper conductors to ferrous or nonferrous terminals, lugs or
fittings.
ANVILOY 1150 material is used in electrobrazing applications where heat balance is important. The ANVILOY 1150
material also has good anti-sticking qualities and good high temperature abrasion and hardness properties. The oxidation resistance of both materials is excellent up to 1100oF.

CONVERSION TABLES INCHES INTO MILLIMETERS


Phone: 866-634-8884

Fax: 866-239-6995

Email: cmw@cmwinc.com

To convert from inches to metric we are including the three tables below to allow conversion from inches into millimeters.
Examples:
From Table I
From Table I
Total
From Table II
From Table I
From Table I
Total
From Table II
From Table II
Total

Convert 0.588 inches into millimeters


0.580 inches = 14.73 millimeters
0.008 inches = 0.203 millimeters
0.588 inches = 14.933 millimeters
Convert 3.065 inches into millimeters
3
inches = 76.2002 millimeters
0.060 inches = 1.524 millimeters
0.005 inches = 0.127 millimeters
3.065 inches =
77.8512 millimeters
Convert 2-51/64 inches into millimeters
2-25/32 inches = 70.6439 millimeters
1/64 inches = 0.3969 millimeters
2-51/64 inches = 71.0408 millimeters

TABLE I
Decimals of
an inch into
millimeters

For Taper
Dimensions
in inches &
millimeters
see Page 7.

Inches

Millimeters

Inches

0.001
0.002
0.003
0.004
0.005

0.025
0.051
0.076
0.102
0.127

0.460
0.470
0.480
0.490
0.500

11.68
11.94
12.19
12.45
12.70

0.006
0.007
0.008
0.009
0.010

0.152
0.178
0.203
0.229
0.254

0.510
0.520
0.530
0.540
0.550

12.95
13.21
13.26
13.72
13.97

0.020

0.508

0.030
0.040
0.050

0.762
1.016
1.270

0.560
0.570
0.580
0.590
0.600

14.22
14.48
14.73
14.99
15.24

0.060
0.070
0.080
0.090
0.100

1.524
1.778
2.032
2.286
2.540

0.610
0.620
0.630
0.640
0.650

15.49
15.75
16.00
16.26
16.51

0.110
0.120
0.130
0.140
0.150

2.794
3.048
3.302
3.56
3.81

0.660
0.670
0.680
0.690
0.700

16.76
17.02
17.27
17.53
17.78

0.160
0.170
0.180
0.190
0.200

4.06
4.32
4.57
4.83
5.08

0.710
0.720
0.730
0.740
0.750

18.03
18.29
18.54
18.80
19.05

0.210
0.220
0.230
0.240
0.250

5.33
5.59
5.84
6.10
6.35

0.760
0.770
0.780
0.790
0.800

19.30
19.56
19.81
20.07
20.32

0.260
0.270
0.280
0.290
0.300

6.60
6.86
7.11
7.37
7.62

0.810
0.820
0.830
0.840
0.850

20.57
20.83
21.08
21.34
21.59

0.310
0.320
0.330
0.340
0.350

7.87
8.13
8.38
8.64
8.89

0.860
0.870
0.880
0.890
0.900

21.84
22.10
22.35
22.61
22.86

0.360
0.370
0.380
0.390
0.400

9.14
9.40
9.65
9.91
10.16

0.910
0.920
0.930
0.940
0.950

23.11
23.37
23.62
23.88
24.13

0.410
0.420
0.430
0.440
0.450

10.41
10.67
10.92
11.18
11.43

0.960
0.970
0.980
0.990
1.000

24.38
24.64
24.89
25.15
25.40

TABLE III
Gage-DecimalMillimeter Conversion
Chart

TABLE II
Fractions of
an inch into
millimeters

Millimeters

Inches
1/64
1/32
3/64
1/16
5/64
3/32
7/64
1/8
9/64
5/32
11/64
3/16
13/64
7/32
15/64
1/4
17/64
9/32
19/64
5/16
21/64
11/32
23/64
3/8
25/64
13/32
27/64
7/16
29/64
15/32
31/64
1/2

Millimeters
0.3969
0.7937
1.1906
1.5875
1.9844
2.3812
2.7781
3.1750
3.5719
3.9687
4.3656
4.7625
5.1594
5.5562
5.9531
6.3500
6.7469
7.1437
7.5406
7.9375
8.3344
8.7312
9.1281
9.5250
9.9219
10.3187
10.7156
11.1125
11.5094
11.9062
12.3031
12.7000

Inches Millimeters
33/64
17/32
35/64
9/16
37/64
19/32
39/64
5/8
41/64
21/32
43/64
11/16
45/64
23/32
47/64
3/4
49/64
25/32
51/64
13/16
53/64
27/32
55/64
7/8
57/64
29/32
59/64
15/16
61/64
31/32
63/64
1

13.0969
13.4937
13.8906
14.2875
14.6844
15.0812
15.4781
15.8750
16.2719
16.6687
17.0656
17.4625
17.8594
18.2562
18.6531
19.0500
19.4469
19.8437
20.2406
20.6375
21.0344
21.4312
21.8281
22.2250
22.6219
23.0187
23.4156
23.8125
24.2094
24.6062
25.0031
25.4001

Gage

Decimal

Millimeter

3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38

.239
.234
.209
.194
.179
.164
.150
.135
.120
.105
.090
.075
.067
.060
.054
.048
.042
.036
.033
.030
.027
.024
.021
.018
.016
.015
.014
.012
.011
.010
.009
.0082
.008
.007
.0064
.006

6.350
5.953
5.556
5.159
4.762
4.365
3.968
3.571
3.175
2.778
2.381
1.984
1.778
1.587
1.422
1.270
1.118
.965
.865
.793
.711
.635
.559
.483
.432
.396
.356
.330
.279
.254
.229
.216
.203
.178
.168
.152

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TAPER DIMENSIONS AND ELECTRODE CODING


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Fax: 866-239-6995

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CAP ELECTRODES
Phone: 866-634-8884

Fax: 866-239-6995

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GCAP ELECTRODES
Phone: 866-634-8884

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Fax: 866-239-6995

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ASIAN CAP ELECTRODES


Phone: 866-634-8884

Fax: 866-239-6995

Email: cmw@cmwinc.com

These economical, quick change caps are made of long lasting, highly efficient CMW 28, CMW 3, CMW 328 copper alloy, precision
manufactured to exacting tolerances in a wide range of standard configurations or to your special requirements.
R

CMW FEMALE ASIAN CAP ELECTRODES


ALL DIMENSIONS MARKED WITH AN (*) ARE COMMON TO EACH CAP IN A HORIZONTAL LINE.

ASIAN TYPE (D)

10mm
(.394)

R8mm
(.315)

10mm
(.394)

Taper 1:9.6
Dia. 13mm (.512)*
Length 20mm (.787)*

CMW 28
CMW 3
CMW 328
R

6mm
(.236)

12.6mm
(.496)

10

10mm
(.394)

ASIAN TYPE (E)

10mm
(.394)

6mm
(.236)

12.6mm
(.496)

R8mm
(.315)

10mm
(.394)

10mm
(.394)

MPC141Z-01
MPC241-01
MPC241Z-02

12.6mm
(.496)

45

MPD141Z-01
MPD241-02
MPD241Z-02

12.6mm
(.496)

6mm
(.236)

40mm
(1.575)
11mm
(.433)

MPB141Z-02
MPB241-02
MPB241Z-07

R8mm
(.315)

Taper 1:9.6
Dia. 16mm (.625)*
Length 23mm (.906)*

10mm
(.394)

MPB141Z-01
MPB241-01
MPB241Z-04

CMW 28
CMW 3
CMW 328

R8mm
(.315)

ASIAN TYPE (F)

40mm
(1.575)
10mm
(.394)

ASIAN TYPE (R)

6mm
(.236)

MPB15Z-11
MPB25-14
MPB25Z-19

11mm
(.433)

11mm
(.433)

MPB15Z-12
MPB25-18
MPB25Z-20

MPC15Z-01
MPC25-02
MPC25Z-05

11mm
(.433)

45

MPD15Z-03
MPD25-05
MPD25Z-04

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METRIC-ISO 5821 STANDARD CAP ELECTRODES


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11

SHANKS FOR FEMALE CAP ELECTRODES


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12

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SHANKS FOR MALE CAP ELECTRODES


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13

STRAIGHT ELECTRODES
Phone: 866-634-8884

14

Fax: 866-239-6995

Email: cmw@cmwinc.com

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STRAIGHT ELECTRODES
Phone: 866-634-8884

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Fax: 866-239-6995

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15

STRAIGHT ELECTRODES
Phone: 866-634-8884

16

Fax: 866-239-6995

Email: cmw@cmwinc.com

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SINGLE BEND ELECTRODES


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Fax: 866-239-6995

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17

DOUBLE BEND ELECTRODES


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18

Fax: 866-239-6995

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CRANK ELECTRODES - COLD FORMED


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19

CRANK ELECTRODES - CASTINGS, FORGED


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20

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SPADE ELECTRODES
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21

GUN ELECTRODES
Phone: 866-634-8884

22

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CHAMELEON/MAX-LIFETM NUT WELDING ELECTRODES


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Fax: 866-239-6995

Email: cmw@cmwinc.com

- Electrode Assemblies 16-37825-XX and


16-37826-XXX may be used with 5/8-18
threaded holders 18-169, 18-170, 18-171,
shown on page 32
- Electrode Assemblies 16-37825-XX and
16-37826-XXX may be used with Platen
Mounted holders (page 61) by using
adapter 18-7743 shown on page 31

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23

CHAMELEON/MAX-LIFETM STUD WELDING ELECTRODES


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- Electrode Assemblies 16-37525-XXX and


16-37526-XXX may be used with 5/8-18
threaded holders 18-169, 18-170, 18-171,
shown on page 32
- Electrode Assemblies 16-37525-XXX and
16-37526-XXX may be used with Platen
Mounted holders (page 61) by using
adapter 18-7743 shown on page 31

24

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SELF-PILOTING NUT WELDING ELECTRODES


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25

NON-PILOTING NUT WELDING ELECTRODES


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Email: cmw@cmwinc.com

Non

26

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ELECTRODE COOLING CHAMBERS & TAPERED ADAPTERS


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www.cmwinc.com

Fax: 866-239-6995

Email: cmw@cmwinc.com

27

STUD WELDING ELECTRODES


Phone: 866-634-8884

28

Fax: 866-239-6995

Email: cmw@cmwinc.com

www.cmwinc.com

BACK-UP ELECTRODES
Phone: 866-634-8884

www.cmwinc.com

Fax: 866-239-6995

Email: cmw@cmwinc.com

29

THREADED ELECTRODES
Phone: 866-634-8884

30

Fax: 866-239-6995

Email: cmw@cmwinc.com

www.cmwinc.com

ADAPTERS
Phone: 866-634-8884

www.cmwinc.com

Fax: 866-239-6995

Email: cmw@cmwinc.com

31

100 SERIES (NON-EJECTOR) WATER COOLED ELECTRODE HOLDER


Phone: 866-634-8884

32

Fax: 866-239-6995

Email: cmw@cmwinc.com

www.cmwinc.com

100 SERIES (NON-EJECTOR) REPLACEMENT PARTS


Phone: 866-634-8884

www.cmwinc.com

Fax: 866-239-6995

Email: cmw@cmwinc.com

33

200 SERIES (EJECTOR) WATER COOLED ELECTRODE HOLDER


Phone: 866-634-8884

34

Fax: 866-239-6995

Email: cmw@cmwinc.com

www.cmwinc.com

200 SERIES (EJECTOR) REPLACEMENT PARTS


Phone: 866-634-8884

www.cmwinc.com

Fax: 866-239-6995

Email: cmw@cmwinc.com

35

300 SERIES PREMIUM (EJECTOR) WATER COOLED ELECTRODE HOLDERS


Phone: 866-634-8884

36

Fax: 866-239-6995

Email: cmw@cmwinc.com

www.cmwinc.com

300 SERIES PREMIUM (EJECTOR) REPLACEMENT PARTS


Phone: 866-634-8884

www.cmwinc.com

Fax: 866-239-6995

Email: cmw@cmwinc.com

37

TYPICAL SET-UP COMBINATIONS USING CMW WELDING PRODUCTS


Phone: 866-634-8884

38

Fax: 866-239-6995

Email: cmw@cmwinc.com

www.cmwinc.com

400 SERIES OFFSET (NON-EJECTOR) WATER COOLED ELECTRODE HOLDERS


Phone: 866-634-8884

www.cmwinc.com

Fax: 866-239-6995

Email: cmw@cmwinc.com

39

400 SERIES OFFSET (NON-EJECTOR) REPLACEMENT PARTS


Phone: 866-634-8884

40

Fax: 866-239-6995

Email: cmw@cmwinc.com

www.cmwinc.com

500 SERIES PREMIUM (EJECTOR) WATER COOLED OFFSET HOLDERS


Phone: 866-634-8884

www.cmwinc.com

Fax: 866-239-6995

Email: cmw@cmwinc.com

41

500 SERIES PREMIUM (EJECTOR) REPLACEMENT PARTS


Phone: 866-634-8884

42

Fax: 866-239-6995

Email: cmw@cmwinc.com

www.cmwinc.com

500 SERIES THREADED PREMIUM (EJECTOR) REPLACEMENT PARTS


Phone: 866-634-8884

www.cmwinc.com

Fax: 866-239-6995

Email: cmw@cmwinc.com

43

600 SERIES UNIVERSAL WATER COOLED ELECTRODE HOLDERS


Phone: 866-634-8884

44

Fax: 866-239-6995

Email: cmw@cmwinc.com

www.cmwinc.com

600 SERIES UNIVERSAL REPLACEMENT PARTS


Phone: 866-634-8884

www.cmwinc.com

Fax: 866-239-6995

Email: cmw@cmwinc.com

45

MALE THREAD TO FEMALE TAPER UNIVERSAL ADAPTERS


Phone: 866-634-8884

46

Fax: 866-239-6995

Email: cmw@cmwinc.com

www.cmwinc.com

T CONNECTORS FOR HOLDERS


Phone: 866-634-8884

www.cmwinc.com

Fax: 866-239-6995

Email: cmw@cmwinc.com

47

800 SERIES NU-TWIST ADAPTERS


Phone: 866-634-8884

48

Fax: 866-239-6995

Email: cmw@cmwinc.com

www.cmwinc.com

800 SERIES NU-TWIST THREADED ADAPTER REPLACEMENT PARTS


Phone: 866-634-8884

www.cmwinc.com

Fax: 866-239-6995

Email: cmw@cmwinc.com

49

NU-TWIST, THREADED SOCKET (OR BUTTON), MALE THREADED BUTTON ELECTRODES

Phone: 866-634-8884

Fax: 866-239-6995

Email: cmw@cmwinc.com

"NU-TWIST" ELECTRODES
R

FLAT FACE "NU-TWIST" ELECTRODE


"Nu-Twist" Electrode
R

TYPE 0 FLAT & 0 TRUNCATED "NU-TWIST" ELECTRODE

K
H
A

30
A&H

JF

800 Series
"Nu-Twist"
Adapter
See page 48

C
E
G

This water baffle is


used in electrodes
over 1" long to assure
water circulation
Type

Size

F
J

Electrode Elect. Ext.


Water
Water
Electrode Part No. Body
Weld
Overall Adapter
CMW 3 CMW 100 Dia. Face Dia. Length Clearance Hole Dia. Hole Depth Seat Dia. From Adapt.
K
J
G
F
H
A
E
C
R

- No tapers or threads
- Can be extracted with a simple turn of hexagon
locking nut
- Any contour in electrode face can be located or
relocated in a given position
- Water circulated to end of electrode for
maximum cooling
- Silver plated contact surfaces on electrode and
base for maximum conductivity
- Provides a simple, low-cost electrode for most
applications
- Electrodes shown can be modified with
contours to provide faces required for most
resistance welding applications

0 Flat

338750
338030

538750
538030

1/2
1/2

1/2
1/2

3/4
1-1/2

---

1/4
1/4

3/8
1-1/8

.625
.625

1/2
1-1/4

0 Trunc. 378750
378030

578750
578030

1/2
1/2

1/4
1/4

3/4
1-1/2

---

1/4
1/4

3/8
1-1/8

.625
.625

1/2
1-1/4

Flat

338751
338031

538751
538031

5/8
5/8

5/8
5/8

3/4
1-1/2

5/16
5/16

1/4
1/4

3/8
1-1/8

.625
.625

1/2
1-1/4

Flat

338012
338052

538012
538052

1-1/4
1-1/4

1-1/4
1-1/4

1
2

5/8
5/8

1/2
1/2

1/2
1-1/2

1.125
1.125

1/2
1-1/2

Flat

338014
338054

1/2
3/4
1
5/8
538014
1-3/4
1-3/4
1-1/2
3/4
2
5/8
538054
1-3/4
1-3/4
Special face contours, lengths and diameters available on special order

1.625
1.625

1/2
1-1/2

THREADED SOCKET(OR BUTTON) ELECTRODES


(USE WITH 900 AND 950 SERIES HOLDERS ON PAGE 51)
ALL DIMENSIONS WITH AN (*) ARE COMMON TO EACH CAP IN A HORIZONTAL LINE.

TRUNCATED FACE

FLAT FACE

RADIUS FACE

OFFSET FACE

30 OFFSET FACE
3/16

#10-32 Thd.

#10-32 Thd.
9/16*

3/16

30

#10-32 Thd.

#10-32 Thd.
SPH.R 2"

3/16

20

21/32

20
3/8

3/8

3/8

3/8

#10-32
Thd.

3/16*
.341*

CMW 28
CMW 3
CMW 100
R
R
R

18-970
18-980
18-990

CMW 28
CMW 3
CMW 100
R
R
R

18-971
18-981
18-991

CMW 28
CMW 3
CMW 100
R
R
R

18-972
18-982
18-992

CMW 28
CMW 3
CMW 100
R
R
R

18-973
18-983
18-993

CMW 28
CMW 3
CMW 100
R
R
R

18-974
18-984
18-994

MALE THREADED BUTTON ELECTRODES


CMW shall supply a variety of nose configurations (examples shown below) made to your
specifications. These electrodes are available in CMW 100, CMW 28 and CMW 3 materials to
meet your various applications. Threads in both Unified (inch) or metric sizes can be supplied.
R

50

www.cmwinc.com

900 SERIES UNIVERSAL & 950 SERIES PADDLE WATER COOLED HOLDERS
Phone: 866-634-8884

www.cmwinc.com

Fax: 866-239-6995

Email: cmw@cmwinc.com

51

HYDRAULIC EQUALIZING ADAPTERS AND ASSEMBLIES


Phone: 866-634-8884

52

Fax: 866-239-6995

Email: cmw@cmwinc.com

www.cmwinc.com

HYDRAULIC EQUALIZING ADAPTERS AND ASSEMBLY REPLACEMENT PARTS


Phone: 866-634-8884

www.cmwinc.com

Fax: 866-239-6995

Email: cmw@cmwinc.com

53

HYDRAULIC EQUALIZING ADAPTERS AND ASSEMBLIES


Phone: 866-634-8884

54

Fax: 866-239-6995

Email: cmw@cmwinc.com

www.cmwinc.com

HYDRAULIC EQUALIZING ADAPTERS AND ASSEMBLY REPLACEMENT PARTS


Phone: 866-634-8884

www.cmwinc.com

Fax: 866-239-6995

Email: cmw@cmwinc.com

55

FIXED UNIT HYDRAULIC EQUALIZING ASSEMBLIES (WATER COOLED)


Phone: 866-634-8884

56

Fax: 866-239-6995

Email: cmw@cmwinc.com

www.cmwinc.com

ADJUSTABLE HYDRAULIC EQUALIZING ASSEMBLY 18-836


Phone: 866-634-8884

www.cmwinc.com

Fax: 866-239-6995

Email: cmw@cmwinc.com

57

1100 SERIES ADJUST-A-PRESSURE WATER COOLED LOW INERTIA ELECTRODE HOLDER


Phone: 866-634-8884

58

Fax: 866-239-6995

Email: cmw@cmwinc.com

www.cmwinc.com

1100 SERIES ADJUST-A-PRESSURE HOLDER REPLACEMENT PARTS


Phone: 866-634-8884

www.cmwinc.com

Fax: 866-239-6995

Email: cmw@cmwinc.com

59

APPLICATION SHEET FOR TYPICAL MULTIPLE SPOT WELDING SETUPS


Phone: 866-634-8884

60

Fax: 866-239-6995

Email: cmw@cmwinc.com

www.cmwinc.com

PLATEN MOUNTED ELECTRODE HOLDERS


Phone: 866-634-8884

Fax: 866-239-6995

Email: cmw@cmwinc.com

TM

www.cmwinc.com

61

MULTI-SPOT WELDER ELECTRODE ADAPTERS


Phone: 866-634-8884

62

Fax: 866-239-6995

Email: cmw@cmwinc.com

www.cmwinc.com

WELDING MACHINE CONTROL CONTACTORS


Phone: 866-634-8884

www.cmwinc.com

Fax: 866-239-6995

Email: cmw@cmwinc.com

63

ACCESSORIES
Phone: 866-634-8884

64

Fax: 866-239-6995

Email: cmw@cmwinc.com

www.cmwinc.com

ACCESSORIES
Phone: 866-634-8884

www.cmwinc.com

Fax: 866-239-6995

Email: cmw@cmwinc.com

65

ELECTRODE DRESSERS
Phone: 866-634-8884

Fax: 866-239-6995

Email: cmw@cmwinc.com

These kits may also be used for cap electrode dressing.

66

www.cmwinc.com

ELECTRODE DRESSERS
Phone: 866-634-8884

www.cmwinc.com

Fax: 866-239-6995

Email: cmw@cmwinc.com

67

WELDING BAR AND ROD STOCK


Phone: 866-634-8884
DIAMETER
THK. WTH.
(INCHES)

RWMA
ALLOY
CLASS NO.

Fax: 866-239-6995

CMW
ALLOY NO.

CMW
PART
NUMBER

Email: cmw@cmwinc.com
WEIGHT/LBS.
INCH

FOOT

Rounds
Rounds
1/8
1/4
3/8
7/16
.482
.482
1/2
1/2
5/8
1/2
5/8
5/8
3/4
7/8
7/8
1.0
1-1/4
1-1/4
1-1/2
1.510
2.0
2.0
2-1/2
3-1/8

2
2
2
2
2
1
2
1
1
3
2
3
2
2
3
2
2
3
2
2
2
3
2
2

CMW3
CMW3
CMW3
CMW3
CMW3
CMW28
CMW3
CMW28
CMW28
CMW100
CMW3
CMW100
CMW3
CMW3
CMW100
CMW3
CMW3
CMW100
CMW3
CMW3
CMW3
CMW100
CMW3
CMW3

58704
58707
58712
58713
50333
65256
58715
64124
64126
75836
58716
75835
58708
58719
75736
58710
58720
59035
58724
52217
58731
75838
58767
51235

.012
.016
.035
.048
.058
.058
.063
.063
.099
.063
.099
.099
.142
.193
.193
.251
.395
.395
.568
.570
1.010
1.010
1.580
2.470

.147
.192
.420
.576
.696
.696
.756
.756
1.188
.756
1.188
1.188
1.704
2.316
2.316
3.012
4.740
4.740
6.816
6.840
12.120
12.120
18.960
29.640

.250 Hex
.375 Hex
.438 Hex
.438 Hex
.500 Hex
.500 Hex
.625 Hex
.750 Hex
.750 Hex
.875 Hex
1.000 Hex
1.000 Hex
1.125 Hex
1.125 Hex
1.250 Hex
1.250 Hex
1.500 Hex

2
3
2
3
2
3
2
2
3
2
2
3
2
3
2
3
3

CMW3
CMW100
CMW3
CMW100
CMW3
CMW100
CMW3
CMW3
CMW100
CMW3
CMW3
CMW100
CMW3
CMW100
CMW3
CMW100
CMW100

79072
79993
79556
79544
76569
75450
68487
58755
78781
58756
58655
55848
52956
79933
73784
67490
50561

.013
.029
.040
.040
.052
.052
.081
.117
.117
.160
.208
.208
.264
.264
.326
.326
.469

.156
.348
.480
.480
.624
.624
.972
1.404
1.404
1.920
2.496
2.496
3.168
3.168
3.912
3.912
5.628

CMW3
CMW3
CMW3
CMW3
CMW3
CMW3
CMW3
CMW3
CMW353
CMW73
ELKALOYD
ELKONITE1W3
ELKONITE10W3
ELKONITE30W3
ELKON100W
ELKON100M

58881
58766
58677
58690
50322
58759
50324
74630

.120
.080
.125
.320
.480
.640
.960
1.440

1.440
.960
1.500
3.840
5.760
7.680
11.520
17.280

Hex
Hex

Squares
and
Rectangles
Squares
and
Rectangles
1/4 x 1-1/2
2
1/2 x 1/2
2
5/8 x 5/8
2
1x1
2
1 x 1-1/2
2
1x2
2
1x3
2
1-1/2 x 3
2
3
4
5
10
11
12
13
14
68

VARIOUS SHAPES AND SIZES


AVAILABLE IN THESE
MATERIALS.
CONSULT CMW INC.
CUSTOMER SERVICE FOR
PRICE AND DELIVERY INFORMATION.

www.cmwinc.com

ELKONITE BAR STOCK


Phone: 866-634-8884

Fax: 866-239-6995

Email: cmw@cmwinc.com

ELKONITE BAR STOCK


TYPICAL PROPERTIES OF ELKONITE MATERIALS
(See CMW Inc. Catalog Series 200)
Elkonite
Material

Density
g/cm or
3
(Mg/m )
Ib/In3

Composition
% by Weight

Electrical
Theoretical
Conductivity
Resistivity Thermal Conductivity Hardness
1
%IACS
(n-ohm-m) Btu-h -ft1-F1 (W-m1-K1) (Rockwell)

Modulus of Rupture
In Bending

ASTM

psi

(MPa)

Specification

1W3
3W3
5W3
10W3
10W53
30W3

55W:45Cu
68W:32Cu
70W:30Cu
75W:25Cu
75W:25Cu*
80W:20Cu

12.50
13.93
14.18
14.84
14.79
15.56

.452
.503
.512
.536
.534
.562

53
50
48
45
28
41

(32.5)
(34.5)
(35.9)
(38.3)
(61.6)
(42.1)

180
160
160
150
85
145

(310)
(280)
(280)
(260)
(150)
(250)

77HRB
90HRB
95 HRB
98 HRB
109 HRB
103 HRB

110.000
130.000
140.000
150.000
200.000
170.000

(758)
(896)
(965)
(1030)
(1380)
(1170)

B702
B702
B702
B702
B702
B702

TC5
TC10
TC20

50WC:50Cu
56WC:44Cu
70WC:30Cu

11.26
11.64
12.65

.408
.421
.457

45
42
30

(38.3)
(41.0)
(57.5)

170
160
140

(290)
(280)
(240)

94 HRB
100 HRB
37 HRC

160.000
180.000
200.000

(1100)
(1240)
(1380)

_
_
_

*Cu Alloy

10W53 FULLY HEAT TREATED

ELKONITE 10W3 ROUND BARS8 INCH LENGTH


FINISHED DIAMETER
1/8
3/16
1/4
5/16
3/8
7/16
1/2
9/16
5/8

PART NUMBER

FINISHED DIAMETER

PART NUMBER

15-140200-64
15-140300-64
15-140400-64
15-140500-64
15-140600-64
15-140700-64
15-140800-64
15-140900-64
15-141000-64

3/4
7/8
1
1-1/8
1-1/4
1-3/8
1-1/2
1-3/4
2

15-141200-64
15-141400-64
15-141600-64
15-141800-64
15-142000-64
15-142200-64
15-142400-64
15-142800-64
15-143200-64

ELKONITE 10W3 RECTANGULAR BARS8 INCH LENGTH


SIZE-INCHES
THICK
WIDTH
1/8
1/4
5/16
3/8
1/2
1/8
5/8
3/4
1
1-1/4
1-1/2
2
4
3/16
3/4
1/4
5/16
3/8
1/2
1/4
5/8
3/4
1
1-1/4
1-1/2
2
4

PART NUMBER
15-140202-64
15-140402-64
15-140502-64
15-140602-64
15-140802-64
15-141002-64
15-141202-64
15-141602-64
15-142002-64
15-142402-64
15-143202-64
15-146402-64
15-141203-64
15-140404-64
15-140504-64
15-140604-64
15-140804-64
15-141004-64
15-141204-64
15-141604-64
15-142004-64
15-142404-64
15-143204-64
15-146404-64

SIZE-INCHES
THICK
WIDTH
5/16
3/8
1/2
5/8
5/16
3/4
1
1-1/4
1-1/2
2
4
3/8
1/2
5/8
3/4
3/8
7/8
1
1-1/4
1-1/2
2
4
1/2
1/2
5/8
3/4
1
1-1/4

PART NUMBER
15-140505-64
15-140605-64
15-140805-64
15-141005-64
15-141205-64
15-141605-64
15-142005-64
15-142405-64
15-143205-64
15-146405-64
15-140606-64
15-140806-64
15-141006-64
15-141206-64
15-141406-64
15-141606-64
15-142006-64
15-142406-64
15-143206-64
15-146406-64
15-140808-64
15-141008-64
15-141208-64
15-141608-64
15-142008-64

SIZE-INCHES
THICK
WIDTH
1-1/2
1/2
2
4
5/8
3/4
1
5/8
1-1/4
1-1/2
2
4
3/4
1
1-1/4
3/4
1-1/2
2
4
1
1-1/4
1
1-1/2
2
4
1-1/4
1-1/4
1-1/2
2
2

PART NUMBER
15-142408-64
15-143208-64
15-146408-64
15-141010-64
15-141210-64
15-141610-64
15-142010-64
15-142410-64
15-143210-64
15-146410-64
15-141212-64
15-141612-64
15-142012-64
15-142412-64
15-143212-64
15-146412-64
15-141616-64
15-142016-64
15-142416-64
15-143216-64
15-146416-64
15-142020-64
15-142420-64
15-143232-64

*Contact Factory For Additional Sizes

www.cmwinc.com

69

FORCE GAUGES
Phone: 866-634-8884

70

Fax: 866-239-6995

Email: cmw@cmwinc.com

www.cmwinc.com

GCAP WELD AND STEPPER SCHEDULE


Phone: 866-634-8884

Fax: 866-239-6995

Email: cmw@cmwinc.com

GCAP ELECTRODE WELD SCHEDULE FOR GALVANIZED STEEL


.020

.030

.035

.040

.050

.060

.078

.093

.125

G-CAP

244

254

254

254

255

255

266

266

266

Pressure

300

400

500

650

750

800

1000

1200

1400

25

25

25

25

30

30

30

35

35

2.0

2.0

2.0

2.0

2.0

to S.C.*

to S.C.*

to S.C.*

to S.C.*

to S.C.*

Metal Thickness

Squeeze cycle
Up-Slope cycle
Upslope
Kiloamps

10

10

12

10

8.5

9.0

9.5

10.0

10.5

11.0

11.5

12.5

13.5

Cool cycle

Weld cycle

10

12

10

10.5

11.0

11.5

12.5

13.5

Weld cycle
Kiloamps

Kiloamps
Cool cycle

Weld cycle

10
13.5

Kiloamps
Hold cycle

10

10

15

20

* S.C. Starting Weld Current

GCAP LINEAR STEPPER


Total Weld Count

500

1,000

3,000

5,000

7,500

10,000

12,000

Total Amps Boost

600

1000

3000

5000

6800

8400

9200

Amps Boost Per

1.20

.88

.60

Weld

The above schedules and stepper is only meant to be a guide and will require adjustments to fit the application.

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71

APPLICATION DATA SHEET


Phone: 866-634-8884

Fax: 866-239-6995

Email: cmw@cmwinc.com

SPOT WELDING DATA


OPTIMUM CONDITIONS
SCHEDULES FOR SPOT WELDING LOW CARBON STEELSAE 1010
Electrode Diameters and Shape*
Flat Face
Thickness
of
Thinnest
Outside
Piece
(Inches)

Maximum d
(Inches)

Min. D
(Inches)

Radius R
(Inches)

0.010
0.021
0.031
0.040
0.050
0.062
0.078
0.094
0.109
0.125

0.125
0.187
0.187
0.250
0.250
0.250
0.312
0.312
0.375
0.375

1/2
1/2
1/2
5/8
5/8
5/8
5/8
5/8
7/8
7/8

2
2
2
3
3
3
3
4
4
4

0.156

0.500

7/8

0.187

0.625

0.250

0.750

Diameter
of Fused Zone
(Approx.)

Minimum Weld
Spacing

Minimum
Contacting
Overlap

Weld Shear Strength


(For Steels Having
Ultimate Tensile
Strength of 90,000
psi and below)
Minimum Strength
(Lbs/Weld)

Dw
(Inches)

S
(Inches)

L
(Inches)
3/8
7/16
7/16
1/2
9/16

Radius Face

1-1/4

Weld
Time
(Cycles)
(60
Hold
Welding
Recommended Weld Cycles Time
Current
Minimum Standard Force
per (Cycles) (Amps.)
Electrode Size (Lbs.) Sec.)
Min.
(Approx.)
4RW
4RW
4RW
5RW
5RW

5RW 2MT
5RW 2MT
7RW 3MT
7RW 3MT
7RW 3MT
Male or Female
Threaded
Male or Female
Threaded
Male or Female
Threaded

160
244
326
412
554

4
6
8
10
14

5
8
10
12
16

4,000
6,500
8,000
8,800
9,600

130
300
530
812
1,195

0.113
0.139
0.161
0.181
0.210

1/4
3/8
1/2
3/4
7/8

670
903
1,160
1,440
1,760

18
25
34
45
60

20
30
35
40
45

10,600
11,800
13,000
14,200
15,600

1,717
2,365
3,054
3,672
4,300

0.231
0.268
0.304
0.338
0.375

1
1-1/8
1-1/4
1-5/16
1-1/2

1MT
1MT
1MT
2MT
2MT

5/8
11/16
3/4
13/16
7/8

2,500

93

50

18,000

6,500

0.446

1-3/4

3,340

130

55

20,500

9,000

0.516

1-1/2

5,560

230

60

26,000

18,000

0.660

1-1/2

PERMISSIBLE SCHEDULE VARIATIONS FOR SPOT WELDING LOW CARBON STEEL


Low Carbon Steel Spot Welding Data ChartSingle Impulse Welding
DATA COMMON TO ALL CLASSES
OF SPOT WELDS

WELDING SET-UP FOR BEST


QUALITYCLASS A WELDS

Electrode
Diam. & Shape
Thickness
of Each
of the
Two
Work
Pieces Min. D
Inches Inches

Diam.
of
Fused
Zone

Max. d
Inches

Min.
Weld
Spacing
(Note 4)
Inches

Min.
Contacting
Overlap
(Note 6)
Inches

WeldWeld
Elecing
Time
trode
Cur(Note 7) Force
rent
Cycles Pounds Amps.

.010
.021
.031
.040
.050

1/2
1/2
1/2
5/8
5/8

1/8
3/16
3/16
1/4
1/4

1/4
3/8
1/2
3/4
7/8

3/8
7/16
7/16
1/2
9/16

4
6
8
10
12

.062
.078
.094
.109
.125

5/8
5/8
5/8
7/8
7/8

1/4
5/16
5/16
3/8
3/8

1
1-1/8
1-1/4
1-5/16
1-1/2

5/8
11/16
3/4
13/16
7/8

14
21
25
29
30

200 4000
300 6100
400 8000
500 9200
650 10300
800
1100
1300
1600
1800

11600
13300
14700
16100
17500

WELDING SET-UP FOR MEDIUM


QUALITYCLASS B WELDS

Average
Tensile
Shear
Strength
14%

WELDING SET-UP FOR GOOD


QUALITYCLASS C WELDS

Diam.
of
Fused
Zone

Diam.
of
Fused
Zone

Inches

Pounds

Inches

Average
Tensile
Shear
Strength
17%
Pounds

Inches

Average
Tensile
Shear
Strength
20%
Pounds

.13
.17
.21
.23
.25

235
530
980
1305
1820

5
10
15
21
24

130
200
275
360
410

3700
5100
6300
7500
8000

.12
.16
.20
.22
.23

200
460
850
1230
1700

15
22
29
38
42

65
100
135
180
205

3000
3800
4700
5600
6100

.11
.14
.18
.21
.22

160
390
790
1180
1600

.27
.31
.34
.37
.40

2350
3225
4100
5300
6900

29
36
44
50
60

500
650
790
960
1140

9000
10400
11400
12200
12900

.26
.30
.33
.36
.39

2150
3025
3900
5050
6500

48
58
66
72
78

250
325
390
480
570

6800
7900
8800
9500
10000

.25
.28
.31
.35
.37

2050
2900
3750
4850
6150

Weld
ElecTime
trode
(Note 7) Force
Cycles Pounds

Welding
Current
Amps.

Weld
Time
(Note 7)
Cycles

ElecWeldtrode
ing
Force Current
Pounds Amps.

NOTES:
1. Low Carbon Steel as hot rolled, pickled, and
slightly oiled with an ultimate strength of
42,000 to 45,000 PSI Similar to SAE 1005
SAE 1010.
2. Electrode Material is CMW 3.
3. Surface of steel is lightly oiled but free from
grease, scale or dirt.
4. Minimum weld spacing is that distance for
which no increase in welding current is necessary to compensate for the shunted current
effect in adjacent welds.

72

5. Radius Face electrodes may be used:


0.010 to 0.031 2" Radius
0.031 to 0.078 3" Radius
0.078 to 0.125 4" Radius
6.

7. Weld time is indicated in cycles of 60 cycle


frequency.

8. Tensile shear strength values are based on recommended test sample sizes:
Direction of Force
Thickness
Width
Length
.000" to .029"
5/8"
3"
.030" to .058"
1"
4"
.059" to .115"
1-1/2"
5"
.116" to .190"
2"
6"
9. Tolerance for machining of electrode diameter d is
.015" of specified dimension.
10. Electrode force does not provide for force to press
ill-fitting parts together.

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PROJECTION WELDING DATA


DESIGN AND WELDING DATA FOR PROJECTION WELDING LOW CARBON STEELS
PROJECTION DESIGN

ELECTRODE DIAMETERS
(d=2 x Projection Diameter)
Diameter of
Fused Zone

Thickness
of
Thinnest
Outside
Piece
Inches

Base
Diameter of
Projection
Dp
Inches

Height of
Projection
H
Inches

Minimum d
Inches

Minimum D
Inches

Electrode
Force
Pounds

Weld Time
(Cycles)
60 Cycles
per Sec.

Hold Time
(Cycles)
Minimum

0.010
0.012
0.014
0.016
0.021
0.025
0.031
0.034
0.044
0.050
0.062
0.070
0.078
0.094
0.109
0.125
0.140
0.156
0.171
0.187
0.203
0.250

0.055
0.055
0.055
0.067
0.067
0.081
0.094
0.094
0.119
0.119
0.156
0.156
0.187
0.218
0.250
0.281
0.312
0.343
0.375
0.406
0.437
0.531

0.015
0.015
0.015
0.017
0.017
0.020
0.022
0.022
0.028
0.028
0.035
0.035
0.041
0.048
0.054
0.060
0.066
0.072
0.078
0.085
0.091
0.110

0.125
0.125
0.125
0.187
0.187
0.187
0.187
0.187
0.250
0.250
0.312
0.312
0.375
0.500
0.500
0.500
0.625
0.625
0.750
0.750
0.875
1.000

1/2
1/2
1/2
1/2
1/2
1/2
1/2
1/2
5/8
5/8
7/8
7/8
7/8
7/8
7/8
7/8
1
1
1
1
1-1/4
1-1/4

50
80
100
115
150
200
300
350
480
580
750
900
1,050
1,300
1,650
1,800
2,300
2,800
3,300
3,800
4,500
6,600

3
3
3
4
6
6
8
10
13
16
21
24
26
32
38
45
60
80
105
125
145
230

3
3
3
4
6
8
8
10
14
16
20
24
30
30
36
40
45
50
50
50
55
60

Welding
Current
Amperes
(Approx.)

Minimum
Contacting
Overlap

Minimum Shear
Strength
(Single Projection

Dw
Inches

Only)
(For Steels
Having Strength
of 100,000 psi
and below)
Pounds

L Inches

0.112
0.112
0.112
0.112
0.140
0.140
0.169
0.169
0.169
0.225
0.225
0.281
0.281
0.281
0.338
0.338
0.437
0.500
0.562
0.562
0.625
0.687

150
200
250
285
380
525
740
900
1,080
1,500
2,100
2,550
2,950
3,700
4,500
5,200
6,000
7,500
8,500
10,000
12,000
15,000

1/8
1/8
1/8
5/32
5/32
3/16
7/32
7/32
9/32
9/32
3/8
3/8
7/16
1/2
5/8
11/16
3/4
13/16
7/8
15/16
1
1-1/4

2,800
3,100
3,400
3,600
4,000
4,500
5,100
5,400
6,500
7,100
8,400
9,200
10,500
11,800
13,300
15,000
15,700
17,250
18,600
20,000
21,500
26,000

NOTES:

Thickness
1. Type of SteelLow Carbon SAE 10100.15% Carbon Maximum.
Dimension
Up to 0.050"
2. Material free of scale, oxide, paint, dirt, etc.
Diameter D ................................................ 0.003"
3. Size of projection determined by thickness of thinnest piece and projection
Height H .................................................... 0.002"
should be on thickest piece.
9. Electrode Material:
4. Data is based on thickness of thinnest sheet for two thicknesses only.
CMW100
ELKONITETC-10
ELKONITE10W3
Maximum ratio between two thicknesses = 3 to 1.
5. See TABLE BELOW for design of punch and die for making projections.
6. Contacting overlap does not include any radii from forming.
7. Projection should be located in center of overlap.
8. Tolerance for Projection Dimensions:
From American Welding Society Recommended Practices for Resistance Welding

Thickness
Over 0.050"
0.007"
0.005"

PUNCH AND DIE DESIGN FOR FORMING WELDING PROJECTIONS

Mat
Thickness

Pt.
No.

.002
C

Dr

.001
E

.001
F

.001
H

Jr

Mat
Thickness

Pt.
No.

.002
C

Dr

.001
E

.001
F

.001
H

Jr

0.010-0.015
0.016-0.021
.025
.031
.034

1
2
3
4
5

3/8
3/8
3/8
3/8
3/8

9/16
9/16
9/16
9/16
9/16

.055
.067
.081
.094
.094

.033
.042
.050
.062
.062

.015
.017
.020
.022
.022

.015
.020
.025
.030
.030

.035
.039
.044
.050
.050

.005
.005
.005
.005
.005

.094
.109
.125
.140
.156

11
12
13
14
15

1/2
1/2
1/2
1/2
5/8

11/16
11/16
11/16
11/16
13/16

.218
.250
.281
.312
.343

.148
.172
.193
.217
.243

.048
.054
.060
.066
.072

.065
.075
.085
.096
.107

.115
.137
.154
.172
.191

.010
1/64
1/64
1/64
1/64

.044
.050
.062
.070
.078

6
7
8
9
10

3/8
3/8
3/8
3/8
3/8

9/16
9/16
9/16
9/16
9/16

.119
.119
.156
.156
.187

.078
.078
.105
.105
.128

.028
.028
.035
.035
.041

.035
.035
.043
.043
.055

.062
.062
.081
.081
.104

.005
.005
.005
.005
.010

.171
.187
.203
.250

16
17
18
19

5/8 13/16
5/8 13/16
11/16 7/8
13/16 1

.375
.406
.437
.531

.265
.285
.308
.375

.078
.085
.091
.110

.118
.130
.143
.175

.210
.229
.240
.285

1/64
1/64
.020
.025

Material: Tool Steel.

Finish all over and harden to 65-68 Rockwell C scale.

Note: All working surfaces of die unit must be polished.

From American Welding Society Recommended Practices for Resistance Welding

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73

APPLICATION DATA SHEET


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SCHEDULE FOR SPOT WELDING STAINLESS STEEL


THICKNESS
T of
THINNEST
OUTSIDE
PIECE
(See Notes
1, 2, 3 and 4
Below)

ELECTRODE DIAMETER
AND SHAPE
(See Note 5)

MINIMUM
CONTACTING
OVERLAP

WELDING
CURRENT
(Approx.)
WELD
TIME
ELECTRODE
FORCE

MINIMUM
WELD
SPACING
(See Note
6 Below)

MINIMUM SHEAR STRENGTH


LB.
Ultimate Tensile Strength of Metal

AMPS
Tensile
Tensile
Strength
Strength
Below
150000 Psi
150000 Psi and Higher

IN.
Approx.

70000
Up to
90000
Psi

3/16
3/16
1/4
1/4

0.045
0.065
0.076
0.082

60
150
185
240

70
170
210
250

85
210
250
320

1/4
1/4
5/16
3/8
3/8

5/16
5/16
5/16
7/16
1/2

0.088
0.093
0.100
0.120
0.130

280
320
370
500
680

300
360
470
600
800

380
470
500
680
930

5500
6300
7000
7500
8300

7/16
7/16
7/16
1/2
9/16

9/16
5/8
11/16
3/4
7/8

0.150
0.160
0.180
0.190
0.210

800
1000
1200
1450
1700

920
1270
1450
1700
2000

1100
1400
1700
2000
2450

9000
10000
11000
12700
14000
15500

5/8
5/8
11/16
3/4
13/16
7/8

1
1-1/8
1-1/4
1-1/2
1-1/2
2

0.220
0.250
0.275
0.290
0.290
0.300

1950
2400
2700
3550
4200
5000

2400
2800
3400
4200
5000
6000

2900
3550
4000
5300
6400
7600

D, IN.,
Min.

d, IN.,
Max.

LB.

CYCLES
(60
Per Sec.)

IN.

IN.

0.006
0.008
0.012
0.014

3/16
3/16
1/4
1/4

3/32
3/32
1/8
1/8

180
200
260
300

2
3
3
4

2000
2000
2100
2500

2000
2000
2000
2200

3/16
3/16
1/4
1/4

0.016
0.018
0.021
0.025
0.031

1/4
1/4
1/4
3/8
3/8

1/8
1/8
5/32
5/32
3/16

330
380
400
520
650

4
4
4
5
5

3000
3500
4000
5000
6000

2500
2800
3200
4100
4800

0.034
0.040
0.044
0.050
0.056

3/8
3/8
3/8
1/2
1/2

3/16
3/16
3/16
1/4
1/4

750
900
1000
1200
1350

6
6
8
8
10

7000
7800
8700
9500
10300

0.062
0.070
0.078
0.094
0.109
0.125

1/2
5/8
5/8
5/8
3/4
3/4

1/4
1/4
5/16
5/16
3/8
3/8

1500
1700
1900
2400
2800
3300

10
12
14
16
18
20

11000
12300
14000
15700
17700
18000

INCHES

DIAMETER
OF
FUSED
ZONE

NOTES:
1. Types of Steel301, 302, 303, 304, 308, 309, 310, 316, 317, 321, 347 & 349
2. Material should be free from scale, oxides, paint, grease and oil.
3. Welding conditions determined by thickness of thinnest outside piece T.
4. Data for total thickness of pile-up not exceeding 4 T. Maximum ratio between
two thicknesses 3 to 1.

90000
Up to
150000
Psi

150000
Psi
and
Higher

5. Electrode Material, CMW 3, CMW 100, or ELKONITE 10W3


6. Minimum weld spacing is that spacing for two pieces for which no special
precautions need be taken to compensate for shunted current effect of adjacent welds. For three pieces increase spacing 30 per cent.

SCHEDULE FOR SEAM WELDING STAINLESS STEEL


ELECTRODE
WIDTH
AND
THICKNESS
SHAPE
T OF
(See Note
THINNEST
5 Below)
OUTSIDE
PIECE
(See Notes 1,
2, 3 and 4
ELECTRODE
Below)
FORCE
INCHES

W, IN., Min.

MINIMUM
CONTACTING
OVERLAP
(See Note
6 Below)

ON TIME

OFF TIME
FOR MAXIMUM
SPEED
(Pressure-Tight)

LB.

CYCLES
(60 Per Sec.)

2 T

CYCLES
4 T

MAXIMUM
WELD SPEED
IN. PER MINUTE
2 T
4 T

WELDS
PER INCH
2 T
4 T

WELDING
CURRENT
(Approx.)
AMPS.

IN.

0.006
0.008
0.010
0.012
0.014
0.016
0.018
0.021
0.025
0.031

3/16
3/16
3/16
1/4
1/4
1/4
1/4
1/4
3/8
3/8

300
350
400
450
500
600
650
700
850
1000

2
2
3
3
3
3
3
3
3
3

1
2
2
2
2
2
2
2
3
3

1
2
2
2
3
3
3
3
4
4

60
67
45
48
51
51
55
55
50
50

67
56
51
55
46
50
50
55
47
47

20
18
16
15
14
14
13
13
12
12

18
16
14
13
13
12
12
11
11
11

4000
4600
5000
5600
6200
6700
7300
7900
9200
10600

1/4
1/4
1/4
5/16
5/16
5/16
5/16
3/8
7/16
7/16

0.040
0.050
0.062
0.070
0.078

3/8
1/2
1/2
5/8
5/8

1300
1600
1850
2150
2300

3
4
4
4
4

4
4
5
5
6

5
5
7
7
7

47
45
40
44
40

45
44
41
41
41

11
10
10
9
9

10
9
8
8
8

13000
14200
15100
15900
16500

1/2
5/8
5/8
11/16
11/16

0.094
0.109
0.125

5/8
3/4
3/4

2550
2950
3300

5
5
6

6
7
6

7
9
8

36
38
38

38
37
37

9
8
8

8
7
7

16600
16800
17000

3/4
13/16
7/8

NOTES:
1. Types of Steel301, 302, 303, 304, 308, 309, 310, 316, 317, 321, 347 & 349.
2. Material should be free from scale, oxides, paint, grease and oil.
3. Welding conditions determined by thickness of thinnest outside piece T.
4. Data for total thickness of pile-up not exceeding 4 T . Maximum ratio between
two thicknesses 3 to 1.

5. Electrode material, CMW 100


6. For large assemblies minimum contacting overlap indicated should be
increased 30 per cent.

From American Welding Society Recommended Practices for Resistance Welding

74

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APPLICATION DATA SHEET


Phone: 866-634-8884

Fax: 866-239-6995

Email: cmw@cmwinc.com

Spot welding galvanized low-carbon steel


Material
Thickness

Electrode
Diameter
And Shape

notes 1, 2,
&3

note 4

NOTES:
1. Material must be free from dirt, grease,
paint etc. prior to welding, but may have
light oil.
2. Two equal metal thicknesses of each gage.
3. Commercial coating weight is 1.25 oz. per
square foot.
4. Electrode Material-RWMA Group A, Class
2. CMW 3.
5. Water Cooling: 2 gallons per minute.
Projections should be larger in diameter for
galvanized than for uncoated material.

In.

In.

Deg.

Lb.

0.022
0.030
0.036
0.039
0.052
0.063
0.078
0.093
0.108
0.123

5/8
5/8
5/8
5/8
5/8
3/4
3/4
3/4
7/8
7/8

3/16
3/16
1/4
1/4
1/4
1/4
5/16
3/8
3/8
3/8

120
120
120
120
120
120
120
120
120
120

300
400
500
650
725
850
1200
1400
1750
2000

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Amps. Cycles
13000
13000
13500
14000
14500
15500
19000
21000
20000
20000

8
10
12
13
18
22
24
30
37
42

In.

Lb.

Inches

Inches

0.15
0.16
0.19
0.21
0.22
0.24
0.28
0.34
0.40
0.48

550
1000
1180
1400
1700
2500
3200
4200
5900
7200

5/8
5/8
3/4
3/4
7/8
1-1/8
1-1/4
1-1/2
1-3/4
2

5/8
5/8
5/8
5/8
11/16
3/4
7/8
1
1-1/8
1-1/8

Projection welding galvanized low-carbon steel


Material
Thickness

Electrode
Net
Diameter Electrode
And Shape
Force

Welding
Current
(Approx.)

Weld Weld
Time Nugget
Size

note 4

Minimum
TensionShear
Strength

Projection
Size

(For Single
Projections
Only)

Inches

In.

In.

Lb.

Amps.

Cycles

In.

0.039
0.063
0.078
0.093
0.108

5/8
5/8
3/4
3/4
7/8

3/8
7/16
1/2
1/2
1/2

250
400
550
750
950

10000
11500
16000
16000
22000

15
20
25
30
33

0.15
0.25
0.25
0.30
0.31

Lb.

Diameter Height
In.
In.

925
2050
2700
4300
4900

0.187
0.218
0.250
0.250
0.250

0.041
0.048
0.054
0.054
0.054

Seam welding galvanized low-carbon steel

NOTES:

From American Welding Society Recommended


Practices for Resistance Welding.

Oc

Inches

notes 1, 2,
&3

1. Material must be free from dirt, grease,


paint etc. prior to welding, but may have
light oil.
2. Two equal metal thicknesses of each gage.
3. Commercial coating weight is 1.25 oz. per
square foot.
4. Electrode Material-RWMA Group A, Class
2. CMW 3.
5. Pressure-tight joints require stripping the
zinc coating prior to welding.
6. Nominal electrode diameter ranges
between 8 to 10 inches.

Net
Welding Weld Weld Minimum Minimum Minimum
Electrode Current Time Nugget Tension- Weld Contacting
Force
(Approx.)
Size
Shear Spacing Overlap
Strength

Material
Thickness

Electrode
Width
And Shape

notes 1, 2,
&3

note 4

Net
Welding
Electrode Current
Force
(Approx.)

Weld
Time

Heat
Time

Inches

In.

In.

0.015
0.036
0.039
0.052
0.063
0.078

3/8
1/2
1/2
1/2
1/2
5/8

1/4
1/4
1/4
1/4
5/16
5/16

Lb.

Amps.

900
1100
1200
1350
1500
1850

15000
18000
19000
20000
19800
23000

Welding Welds Minimum


Speed
Per
Contacting
Inch
Overlap

Cool
Time

Cycles Cycles In./Min.


2
4
4
5
8
10

2
2
3
1
2
7

120
60
60
90
54
30

W/In.

Inches

7.5
10.0
9.0
7.0
7.0
7.0

3/8
1/2
1/2
9/16
5/8
11/16

75

DATA SHEET
Phone: 866-634-8884

Fax: 866-239-6995

RECOMMENDED ELECTRODE MATERIALS

2.
3.
4.
5.

The process of resistance welding makes it possible to join most metals, similar or dissimilar. Bonds of adequate strength are obtainable for an extremely wide range of applications.
Selecting electrodes of the proper alloy is a most important consideration in producing good
welds at the required speed. The chart below is a valuable guide to this selection.

Email: cmw@cmwinc.com

Metallurgical properties
Nature of resultant weld or alloy
Weld strength
Relative accuracy in control of welding conditions necessary

The weldability of metals as shown in the chart applies only when conventional spot welding methods are used on similar thicknesses of material. However, many metal combinations which are listed as having a poor weldability may be satisfactorily joined by using a
special setup or procedure.
There is a CMW Alloy for each specific welding application. Experienced CMW engineers
will provide assistance with special problems.

The weldability of two materials as expressed in the following chart has been derived after
careful laboratory study and field survey of many factors which influence the welding or
resultant weld of the metals. The factors include:
1. Thermal and electrical conductivity

Electrode Materials For SPOT WELDING Similar and Dissimilar Metals


Tungsten
Molybdenum

Magnesium

Nickel
Alloys

Nickel

Stainless
Steel

Chrome
Steel

Galvanized
Steel
Zn. Plate

Cadmium
Plate

Terne
Plate

Tin
Plate

C. R.
Steel

Scaly
Steel

Phosphor
Bronze

Silicon
Bronze

Nickel
Silver

Cupro
Nickel

Brass
Yellow

Brass
Red

Copper

Aluminum
Alloys

Commercially Pure
Titanium

II

Aluminum
2S-3S
Aluminum Alloys
Duralumin
52S-17S-24S

E II D II D II
I 34 I 25 I 25

D II E II H V C I C I
I 5 I 2 I 2 I 1 I 1

C I E II E II H I H II E
I 1 5 I 2 I 2 3 I 243 I 3 8 I

D I D I D I
I 394 I 394 I 394

E II D II D II
I 34 I 25 I 25

D II E II E V D 1
I 6 I 2 I 2 I 1

H I H I H I
V 394 V 394 V 394

H II D II D II D II D II D II E II K V
V 34 V 56 V 56 V 56 D 56 V 6 V 6 V 2

H I H
V 6 V

H II D II D II D II D II D II E II
II 3 4 V 6 V 6 V 6 V
II
II 5 6

BrassRed
5-25% Zinc

H I D II D II H II H II H
II 5 V 6 V 6 V
V
V

E I D II D II H II H II E
II 5 IV 6 II 6 IV IV IV

BrassYellow
25-40% Zinc

D I C II C VI E II I E II E
II 2 5 II
II
II 2 II 2 8 II

Cupro-Nickel

D I C II C VI E II I E II E
II 2 5 II
II
II 2 II 2 8 II

Nickel Silver

D I C II D II E II I E II E
II 2 5 II
II
II
II 8 II

Silicon Bronze

Phosphor Bronze
Grades A, C, & D

E I D II D II E II I E II E
II 2 5 II
II
II
II 8 II

Scaly
H. R. Steel

D II
II 3

Galvanized Steel
Zinc Plate

Cadmium Plate

II

II
6

E I E
II 2 II

E I E
II
II

E I E
II
II

D II D II B II B II C II C I B
II 3 II 3 III
II 8 II
II
II

II
2

II
2

II

II

D II I D II D II D I D
I

II 3 7

II

7 I II 7 8 I II

E II E I D I D II C II I C II D
I 9 I 59 I 39 I 9 I
I 8 I

E II E I D I D II C II C II C
3
II 9 I 5 9 I
I 9 I
I 8 I

II
9

II

III

Chrome Plate

D II D II B
II 8 II 8 II

Stainless Steel
18-8 Type

DII
I 25

D II D III A IIIII
III
1
II
I
II
II

Nickel
Grade A

D II
II 2 5

C II B II
II 1 II 1

Nickel Alloys
Monel Nichrome
(High Res.)

D II
II 2 5

B II
II 1
D I
I 15

Magnesium
Alloys

D II
II 2 5

II
8

B II
II 8

H I
V 6

II
2

II
2

II

II

II
6

III

II

III

E II C II C II C II C II C II
IV 3 4 IV 1 IV 1 IV 1 IV 1 II 1

E I H
II 2 II

E I H
II 2 II

E I H
II
II

E I H
II
II

C I E
II
II

II
7
II
7

II
7

II
7

II
7

E II C II C II C II B II
II 3 II 1 II 1 II
II 1
E II C II C II B II
II 3 II 1 II 1 II 1
D II C II B II
II 3 II 1 II 1
D II B II
II 3 II 1
A II
II 1

D I E

I
l
II
II
I
I
I
II 6 7
II 6 7
II 6 7
II 7

C I D
I 69 I

II

69

D I
I 69

C I C I
I 6 I 6

E II E I D II D II C II C II C I C I II
I 9 I II 5 9 I II 3 II 9 I
I 8 9 I 9 I II 9
E II E I D I D II C II C II C I
I 9 I 5 I 3 I 9 I
I 8 I 9

II

E I E I II E I
IV 6 IV 6 IV 6

H II

E I E
II 2 II

DII
II 8

Molybdenum
Tungsten

II

39

Tin Plate

Terne Plate

II

34
9
I

C. R. Steel
H. R. SteelClean

76

C I E II E II H I H II E I D I D I D I
2
2
1
3
23
I 5 I 5 I 3 I 4 I 8 I 394 I 394 I 394 I 394

H II H I E II E II H I H II H
V 3 6 V 243 V 3 4 V
V 3 V 5 V

CopperPure

C. P.
Titanium

Aluminum

WELDABILITY
As a basis for comparison cold
rolled (mild) steel has been
chosen and its weldability
designated as excellent.
A - Excellent E - Poor
B - Very Good H - Very Poor
C - Good
K - Impractical
D - Fair
ELECTRODES
I - CMW 28
II - CMW 3
III - CMW 100
IV - ELKONITE 10W3
V - ELKON 100M*
VI - ELKONITE 1W3 or TC-5

BLOCK INTERPRETATION
WELDABILITY

ELECTRODE
AGAINST

ELECTRODE
AGAINST

SPECIAL
INFORMATION

*ELKON 100 W may be substituted.


ELKONITE 10W3 or TC-10 may be
interchanged.
Electrode materials in circles are
second choice.

ELECTRODES
I - CMW 28
II - CMW 3
III - CMW 100
IV - ELKONITE 10W3
V - ELKON 100M*
VI - ELKONITE 1W3 or TC-5
*ELKON 100 W may be substituted.
ELKONITE 10W3 or TC-10 may be
interchanged.
Electrode materials in circles are
second choice.
SPECIAL INFORMATION
1. Good weld strength.
2. May be welded under special conditions.
3. Low weld strength.
4. No actual weld nugget occurs, a stick is
obtained.
5. Welding conditions must be accurately
controlled.
6. Keep electrode clean to prevent sticking
to the work.
7. Good practice recommends cleaning
steel before welding.
8. Use one flat tip to minimize distortion or
discoloration.
9. Coating may dissolve in other metals or
burn away.

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RESISTANCE WELDING ELECTRODE MAINTENANCE


Phone: 866-634-8884

Fax: 866-239-6995

Email: cmw@cmwinc.com

This Chart shows graphically the importance of Electrode maintenance. This is not only important from the quality of the weld,
which is of first importance, also extra load added to the welding machine and equipment. Read the data on the chart, you can
then draw your own conclusions.

YOU CANT AFFORD TO NEGLECT YOUR ELECTRODES!


Keep your Electrodes dressed for maximum production and quality welds.

A TIP DRESSER WILL PAY DIVIDENDS!


We can supply you with hand operated Tip Dressers or Pneumatic Power Driven Dressers. Design or type will depend on your
production requirements. Pages 66 & 67.

RESISTANCE WELDING

012

049

077

110

197

307

442

2,460
amperes only
would be
required ()

9,823
amperes
would be
required ()

15,337
amperes
would be
required ()

22,100
amperes
would be
required ()

39,300
amperes
would be
required ()

61,350
amperes
would be
required ()

88,500
amperes
would be
required ()

127,640 lbs. sq. in.


pressure (*)

31,960 lbs. sq. in.


pressure (*)

20,470 lbs. sq. in.


pressure (*)

14,200 lbs. sq. in.


pressure (*)

7,990 lbs. sq. in.


pressure (*)

5,120 lbs. sq. in.


pressure (*)

3,500 lbs. sq. in.


pressure (*)

RESULT:
Four times too
much pressure,
current. Very
severe indentation
and spitting
from high
current density.

RESULT:
Correct pressure,
current, tips.
Excellent weld.
This is the size
tip (new) for
which the
pressure, time,
and current
are adjusted.

RESULT:
Only 60% of
proper pressure,
current.
Borderline weld.
Lower strength.
Last diameter
size tolerated
unless current
and pressure
were set between
the 1/4 and 5/16
size tips.

RESULT:
Only 45% of the
required pressure
and current.
Welds would be
unacceptable.
If the current
or time were
increased with
tips in this
condition a
large weak weld
would result.

RESULT:
Only 25: of
required current
and pressure.
No weld would
be made if tips
were left in
this condition.

RESULT:
Only 16% of
required current
and pressure.
This is a very
serious condition
and the only cure
is to dress the
tips back to (B)
condition.

RESULT:
Only 11% of
needed current
and pressure.
This is an
absurd (though
often seen)
condition that
only heats a spot.

CORRECTION:
Cut pressure
to 1/4
Cut current
to 1/4

() Current density required for this gage to be 200,000 amps per sq. in.
Setting is 9,900 amps for condition (B)

(*) Five inch diameter air cylinder A 80 lbs. air pressure1570 lbs. on ram.
Reproduced by permission of McGraw-Hill Book Company, Inc.

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77

WELDING ELECTRODE / CAP EVALUATION FORM


Phone: 866-634-8884

Fax: 866-239-6995

Email: cmw@cmwinc.com

Facility _______________________________________________________
Location ______________________________________________________
Contact ____________________________ Phone ______________ Fax _____________ Date _______________

Equipment --- Plant/Line # _________________________________________


Fixed
Auto

Press

Hand

Pinch

Scissor

Other
(Specify)

Old

Good

Poor

Number of
Steps

Linear

Non-linear

None

UP-SLOPE
CAPABILITY

Yes

No

PULSE
CAPABILITY

Yes

No

Schedules
per SCR

Transformers
per SCR

Guns per
Transformer

Transformer
Taps

Robot

TYPE
C Gun

Online

Offline

Other
(Specify)

Comment

GUN STYLE
New

CONDITION

STEPPER
CAPABILITY

NUMBER OF

Transformer
KVA

Workpieces (Materials)
CHECK ONE (per workpiece)
POSITION

THICKNESS

Bare Steel

Good

Poor

Aluminized

Zn Electroplate

Galvanneal

Hot Dipped
Galvanized

Organic

Outside
Inside
Inside
Outside
Comments

FIT-UP

ELECTRODES
NOSE
STYLE
MATERIAL
TAPER
STYLE

78 78

ALIGNMENT

Other

(Pointed)

(Dome)

(Flat)

(Offset)

(Truncated)

(Radius)

(Specify)

Class 1

Class 2

Class 20
(DSC)

Other
(Specify)

Female

Male

Good

Poor

Comments

Requires
Backup

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RESISTANCE WELDING DOS AND DONTS


Phone: 866-634-8884

Fax: 866-239-6995

Email: cmw@cmwinc.com

DOS AND DONTS FOR RESISTANCE WELDING ELECTRODES


DOS
1.

Use the proper electrode material for the job


you are doing.

2.

Use standard electrodes wherever possible.

3.

Use the most suitable tip diameter for the


thickness of stock being welded.

4.

Use open sight drains to observe more


readily the water flow through the holders.

5.

Connect the water inlet hose to the proper


holder inlet so that the water flows through the

DONTS
1. Never use unidentified electrodes or electrode
materials.
2. Avoid special, offset or irregular tips when the job
can be done with a standard straight tip.
3. Dont use small tips on heavy gauge welding jobs
or large tips on small work.
4. Dont forget to turn on the cooling water full force
before starting to weld.

center cooling tube first.


6.

Internally cool the spot welding tips with cool


water flowing at a rate of at least 1/2 gallon
per minute through each tip.

7.

Be sure the internal water cooling tube of the


holder projects into the tip water hole to
within 1/4" of the tip hole bottom.

8.

Adjust the internal water cooling tube of the


holder to the proper height when changing to
a different length tip.

9.

Be sure top of adjustable water cooling tube in

5. Never use water hose that will not fit the holder
water connection nipples snugly.
6. Do not allow water connections to become leaky,
clogged or broken.
7. Avoid using holders with leaking or deformed
tapers.
8. Never use electrode holders that do not have an
adjustable internal water cooling tube.
9. Do not permit adjustable water tube to be frozen

holders is cut at an angle so as to avoid

by accumulation of deposits. A few drops of oil

jamming tip down and shutting water off.

periodically will keep the tube free.

10. Place a thin film of cup grease on the tip


taper prior to inserting in the holder, to make
it easier to remove.
11. Use ejector type holders for easy removal of tips
and to avoid damage to tip tapers.
12. Keep the tip taper and holder taper clean, smooth
and free of foreign deposits.
13. Dress spot welding electrodes frequently to
maintain the quality of the welds.
14. Dress electrodes in a lathe to their original

10. Do not allow electrodes to remain idle in tapered


holder seats for extended periods.
11. Dont use pipe wrenches or similar tools in
removing electrodes.
12. Avoid using white lead or similar compounds to
seal a leaking taper.
13. Never permit a spot welding tip to mushroom
enough to make dressing difficult.
14. Never dress electrodes with a coarse file.

contour whenever possible.


15. Use a rawhide or rubber mallet for striking holder
or tips in aligning operations.
16. Provide flood cooling on both sides of the seam
welding wheel.
17. Use properly designed knurling wheels to maintain
proper seam welding wheel shape.

15. Dont pound on the holder or tip with a steel


hammer in aligning the welder arms.
16. Avoid the use of seam welder wheels too thin to
stand the heat or pressure of your job.
17. Do not permit seam welding wheel to run off the
corners of the work being welded.

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79

SKETCHES AND NOTES


Phone: 866-634-8884

80

Fax: 866-239-6995

Email: cmw@cmwinc.com

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