Application

Resistance Welding Electrodes

Threaded electrodes and caps for guns, robots and fixtures

Overview

Why tungsten-copper here

Spot and projection welding electrodes live a harder life than their size suggests: thousands of weld cycles per shift, each one a thermal shock. Tungsten-copper facings and shanks keep their shape where pure copper deforms, cutting dressing frequency and nugget-size variation on high-strength and coated steels.

We machine threaded electrodes to drawing — metric, UNC/UNF and special forms — on a 15-lathe cell, with thread gauges verified per batch. Rods and blocks in both W/Cu grades are stocked for shops that machine their own caps, holders and shanks.

Less dressing, steadier welds

W/Cu faces resist mushrooming, so nugget size stays stable across the shift.
Threaded to drawing

Metric, UNC/UNF or special thread forms, batch-verified with thread gauges.
Stock for in-house machining

Rods and blocks in W/Cu 75/25 and 70/30 for caps, holders and shanks.
Robot-cell ready

Repeatable dimensions keep automated stations running without re-teaching.

In depth

Application notes

Electrode shapes and what they solve

The consumable geometry is chosen by the weld, not the catalogue: radius-face caps for general spot work, flat and domed faces for projection dies, tapered shanks for robot guns where tip-dress access is tight. We cut all of them from the same infiltrated stock — which means the alloy you validated is the alloy you keep getting, order after order.

Internal cooling matters as much as face shape. We machine water passages to your holder specification, because a W/Cu face only delivers its thermal advantage when the heat it conducts out actually leaves the electrode.

Coated and high-strength steels

Galvanized and Zn-Al coated sheet is where copper-alloy electrodes historically died young: zinc alloys into the face, builds an insulating glaze, and forces earlier dressing. The tungsten skeleton in W/Cu resists that pickup mechanically — the face stays metallic longer, dressing intervals stretch out, and nugget size stops wandering across the shift.

On high-strength steels the load is mechanical instead: higher electrode force drives face growth on soft alloys. This is the case for W/Cu 75/25 facings — the selection logic is covered in detail in our alloy comparison guide.

Consumption rhythms we can serve

Automated gun cells consume electrodes on a predictable cycle, and our supply model is built around it: no minimum order, 10–14 days on standard shapes, and repeat orders machined to the same drawing revision every time. For robot cells running mixed consumables, thread form and shank geometry stay identical across batches — verified with thread gauges and dimensional records.

Shops that machine their own caps and shanks buy our rods and blocks instead: stock shapes in both grades, rough-machined or ground, shipped vacuum-packed with foam lining.

Related: Electrode rods & blocks

Supplied from our floor