The shank (base metal) and tip (tungsten or molybdenum) of a resistance welding electrode are usually joined by brazing or press-fitting. However, these joining methods present issues such as variations in joining quality and short electrode lifespans. We previously solved these problems by using our proprietary Non-Defective Bonding (NDB) method. The NDB method provides more reliable joint quality than conventional methods. In this study, we visualized the surface temperatures of different electrodes and confirmed that the NDB method improves heat dissipation speeds. We also proved that both the maximum temperatures of the electrode and workpiece and the heat dissipation speed are influenced by the tip protrusion length. These findings indicate that adjusting the chip protrusion length can effectively control the amount of heat generated by the electrode.

2_Comparison_of_heat_dissipation_of_electrodes_for_resistance_welding_in_NDB_joining.pdf