Resistance welding electrode cap

Claim 2

A cold formed or machined unitary resistance welding electrode cap formed of dispersion strengthened copper and adapted to be internally cooled with a flow of coolant, said cap having a main body portion including an inner recess for coolant at its proximal end and an elongated nose portion terminating in an integral welding tip face at its distal end and an intermediate root portion connecting the nose portion and the main body portion, and wherein said nose is slightly tapered, is at least about 5 mm long from root to tip, has horizontal cross sectional area of tip not substantially in excess of about 4/10ths that of said main body portion at its greatest extent, has nose length to nose tip width ratio not substantially in excess of about 2, and is entirely of dispersion-strengthened copper except for optional jacketing of at least part of the main body portion with another metal.

Claim 3

The cap of claim 1 wherein all horizontal cross sections are circular, said nose is coaxial with said main body portion, and the maximum outside diameter of said main body portion is between about 10 and about 30 mm.

Claim 4

The cap of claim 1 wherein said electrical and coolant connection has a locking taper.

Claim 5

The cap of claim 1 wherein the tip of said nose has a conformation that is longer than it is wide, and said tip is either round, straight or bent.

Claim 6

The cap of claim 1 wherein the dispersion-strengthened copper contains dispersion-strengthened refractory oxide in a volume concentration which is the same as that of alumina at a concentration equivalent to about 0.2-0.7 weight percent elemental aluminum.

Claim 7

The cap of claim 5 wherein said dispersion-strengthened copper contains alumina in a concentration between about 0.25 and about 0.6 weight percent measured as elemental aluminum.

Claim 8

A process for welding steel surfaces together, at least one of which steel surfaces includes a zinc-coating, which comprises contacting opposite sides of the weld joint with resistance welding electrodes and passing an electric current therethrough of sufficient density to weld the surfaces together, the electrode or electrodes in contact with a zinc coated surface or surfaces including a cold formed or machined unitary resistance welding electrode cap formed of dispersion strengthened copper containing between about 0.25% and about 0.6% alumina by weight measured as equivalent aluminum, cooling said electrode cap internally with a flow of coolant, said electrode cap having a main body portion including an inner recess for receiving coolant at its proximal end, and a nose portion terminating in an integral welding tip face at its distal end, and an intermediate root portion disposed between the nose portion and the main body portion, and wherein said nose is slightly tapered, is at least about 5 mm long from root to tip, has horizontal cross sectional area of tip not substantially in excess of about 4/10ths that of said main body portion at its greatest extent, has nose length to nose tip width ratio not substantially in excess of about 2, and is entirely of dispersion-strengthened copper except for optional jacketing of at least part of the main body portion with another metal.

Claim 9

A process for welding steel surfaces together, at least one of which steel surfaces includes a zinc-coating, which comprises contacting opposite sides of the weld joint with resistance welding electrodes and passing an electric current therethrough of sufficient density to weld the surfaces together, the electrode or electrodes in contact with a zinc coated surface or surfaces including a cold formed or machined unitary resistance welding electrode cap formed of dispersion strengthened copper containing between about 0.25% and about 0.6% alumina by weight measured as equivalent aluminum, cooling said electrode cap internally with a flow of coolant, said electrode cap having a main body portion including an inner recess for receiving coolant at its proximal end, and a nose portion terminating in an integral welding tip face at its distal end, and an intermediate root portion disposed between the nose portion and the main body portion, and wherein said nose is slightly tapered, is at least about 5 mm long from root to tip, has horizontal cross sectional area of tip not substantially in excess of about 4/10ths that of said main body portion at its greatest extent, has nose length to nose tip width ratio not substantially in excess of about 2, and is entirely of dispersion-strengthened copper except for optional jacketing of at least part of the main body portion with another metal.

Claim 10

The process of claim 7 wherein said zinc-coated metal is double-sided galvanized steel.

Claim 11

A process as defined in claim 7 wherein the welding tip face has a transverse convex profile.

Claim 12

A process as defined in claim 7 wherein the root portion includes a concave profile between the main body portion and the welding tip.

Claim 13

A process as defined in claim 7 wherein the nose portion has a taper between zero and 20°.

Claim 14

A process as defined in claim 7 wherein the nose portion has a taper between zero and 10°.

Claim 15

A process for welding steel surfaces together, at least one of which steel surfaces includes a zinc-coating, which comprises contacting opposite sides of the weld joint with resistance welding electrodes and passing an electric current therethrough of sufficient density to weld the surfaces together, the electrode or electrodes in contact with a zinc coated surface or surfaces including a cold formed or machined unitary resistance welding electrode cap formed for dispersion strengthened copper cooling said electrode cap internally with a flow of coolant, said electrode cap having a main body portion including an inner recess for receiving coolant at its proximal end, and a nose portion terminating in an integral welding tip face at its distal end, and an intermediate root portion disposed between the nose portion and the main body portion, and wherein said nose is slightly tapered, is at least about 5 mm long from root to tip, has horizontal cross sectional area of tip not substantially in excess of about 4/10ths that of said main body portion at its greatest extent, has nose length to nose tip width ratio not substantially in excess of about 2, and is entirely of dispersion-strengthened copper except for optional jacketing of at least part of the main body poriton with another metal.

Claim 16

A process for welding steel surfaces together, at least one of which steel surfaces includes a zinc-coating, which comprises contacting opposite sides of the weld joint with resistance welding electrodes and passing an electric current therethrough of sufficient density to weld the surfaces together, the electrode or electrodes in contact with a zinc coated surface or surfaces including a cold formed or machined unitary resistance welding electrode cap formed for dispersion strengthened copper cooling said electrode cap internally with a flow of coolant, said electrode cap having a main body portion including an inner recess for receiving coolant at its proximal end, and a nose portion terminating in an integral welding tip face at its distal end, and an intermediate root portion disposed between the nose portion and the main body portion, and wherein said nose is slightly tapered, is at least about 5 mm long from root to tip, has horizontal cross sectional area of tip not substantially in excess of about 4/10ths that of said main body portion at its greatest extent, has nose length to nose tip width ratio not substantially in excess of about 2, and is entirely of dispersion-strengthened copper except for optional jacketing of at least part of the main body poriton with another metal.