# WELD AND STEPPER SCHEDULE

GCAP#
Phone: 866-RES-WELD (737-9353)

Fax: 714-252-5335

www.seedorffwelders.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.

APPLICATION DATA SHEET

Phone: 866-RES-WELD (737-9353)

Fax: 714-252-5335

www.seedorffwelders.com

SPOT WELDING DATA

OPTIMUM CONDITIONS
SCHEDULES FOR SPOT WELDING LOW CARBON STEELSAE 1010
Electrode Diameters and Shape*
Flat Face

Radius 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

1-1/4

Diameter
of Fused Zone
(Approx.)

Minimum Weld
Spacing

Minimum
Contacting
Overlap

Dw
(Inches)

S
(Inches)

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

Weld
Weld Shear Strength
Time
(For Steels Having
(Cycles)
Ultimate Tensile
(60
Hold
Welding
Strength of 90,000
Recommended Weld Cycles Time
Current
psi and below)
Minimum Standard Force
per (Cycles) (Amps.)
Minimum Strength
Electrode Size (Lbs.) Sec.)
Min.
(Approx.)
(Lbs/Weld)
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

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

4RW 1MT
4RW 1MT
4RW 1MT
5RW 2MT
5RW 2MT
5RW 2MT
5RW 2MT
7RW 3MT
7RW 3MT
7RW 3MT
Male or Female
Threaded
Male or Female
Threaded
Male or Female
Threaded

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

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

WELDING SET-UP FOR BEST

QUALITYCLASS A WELDS
Diam.
of
Fused
Zone

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.

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.

APPLICATION DATA SHEET

Phone: 866-RES-WELD (737-9353)

Fax: 714-252-5335

www.seedorffwelders.com

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

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

Electrode
Force
Pounds

Weld Time
(Cycles)
60 Cycles
per Sec.

Hold Time
(Cycles)
Minimum

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.
CMW"100
ELKONITE"TC-10
ELKONITE"10W3
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.

From American Welding Society Recommended Practices for Resistance Welding

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

APPLICATION DATA SHEET

Phone: 866-RES-WELD (737-9353)

Fax: 714-252-5335

www.seedorffwelders.com

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)

WELDING
CURRENT
(Approx.)
WELD
TIME
ELECTRODE
FORCE

MINIMUM
WELD
SPACING
(See Note
6 Below)

DIAMETER
OF
FUSED
ZONE

MINIMUM SHEAR STRENGTH

LB.
Ultimate Tensile Strength of Metal

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

D, IN.,
Min.

d, IN.,
Max.

LB.

CYCLES
(60
Per Sec.)

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

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

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

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

INCHES

MINIMUM
CONTACTING
OVERLAP

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

IN.

IN.

2000
2000
2000
2200

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

3000
3500
4000
5000
6000

2500
2800
3200
4100
4800

6
6
8
8
10

7000
7800
8700
9500
10300

10
12
14
16
18
20

11000
12300
14000
15700
17700
18000

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
4 T

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.

2 T

WELDING
CURRENT
(Approx.)

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

APPLICATION DATA SHEET

Phone: 866-RES-WELD (737-9353)

Fax: 714-252-5335

www.seedorffwelders.com

Spot welding galvanized low-carbon steel

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.

Material
Thickness

Electrode
Diameter
And Shape

notes 1, 2,
&3

note 4

Oc

Inches

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

Material
Thickness

Electrode
Net
Diameter Electrode
And Shape
Force

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

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.

Amps. Cycles

Projection welding galvanized low-carbon steel

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
W

Welding Welds Minimum

Speed
Per
Contacting
Inch
Overlap

Cool
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

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

DATA SHEET
Phone: 866-RES-WELD (737-9353)

Fax: 714-252-5335

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.

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.

www.seedorffwelders.com

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

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

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

BrassYellow
25-40% Zinc

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

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

C. R. Steel
H. R. SteelClean
Scaly
H. R. Steel

D II
II 3

II

E I E
II 2 II

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

H II

II 3 7

II

II

II

II
2
II

II

D II D II D I D

I
7 I II 7 8 I II

Terne Plate

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

II
9
II

II

H I
V 6

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

II
2
II
2
II

II

II
6

C I D
I 69 I

II

69

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

D I E

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

III

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

BLOCK INTERPRETATION

II
7

D I
I 69

C I C I
I 6 I 6

WELDABILITY

ELECTRODE
AGAINST

ELECTRODE
AGAINST

SPECIAL
INFORMATION

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
III

Chrome Plate

DII
II 8

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
Molybdenum
Tungsten

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

Cadmium Plate

II

39

Tin Plate

Galvanized Steel
Zinc Plate

II

34
9

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

CopperPure

C. P.
Titanium

Aluminum

D II
II 2 5

II

WELDABILITY
As a basis for comparison cold rolled (mild)
steel has been chosen and its weldability
designated as excellent.
AExcellent
EPoor
BVery Good
HVery Poor
CGood
KImpractical
DFair

B II
II 8
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.
2.
3.
4.
5.
6.
7.
8.
9.

Good weld strength.

May be welded under special conditions.
Low weld strength.
No actual weld nugget occurs, a stick is obtained.
Welding conditions must be accurately controlled.
Keep electrode clean to prevent sticking to the work.
Good practice recommends cleaning steel before welding.
Use one flat tip to minimize distortion or discoloration.
Coating may dissolve in other metals or burn away.

RESISTANCE WELDING ELECTRODE MAINTENANCE

Phone: 866-RES-WELD (737-9353)

Fax: 714-252-5335

www.seedorffwelders.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

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.