Evolving from our vast experience working with engineers and technical teams to perfect the art and science of automated micro spot welding applications, Metal Cutting offers a range of specialty refractory metal electrode products, including copper tungsten electrodes, silver tungsten electrodes, and pure tungsten electrodes. Our electrode materials expertise is in tungsten, molybdenum, and their alloys, including copper tungsten and silver tungsten as well as carbide compositions and heavy metal electrodes. Our electrodes are used in high-speed, large volume automated resistance spot welding manufacturing environments and are also excellent for die sinker EDM, especially when machining tungsten carbide workpieces.
Designed for Resistance Spot Welding and Die Sinker EDM
Among our electrode materials, copper tungsten is by far the most popular for both resistance spot welding and die sinker EDM applications. Our electrode design and construction — utilizing not only the proper electrode materials and correct tip and shank profiles, but also an exceptional bonding method in the manufacture of the electrode itself — help to ensure superior weld quality.
For high-volume production, our resistance spot welding electrodes achieve the metal-to-metal surface contact and pressure needed for the best weld possible. Our non-defective bonding (NDB) technology (which you can read about in our white paper Better Together: Non-Defective Bonding of Resistance Spot Welding Electrodes creates a resistance welding electrode that delivers better thermal conductivity, lower electrical resistance, and lower electrical conductivity than copper to the junction. Unlike silver brazing and press fit techniques for bonding an electrode to a shank, our NDB method provides maximum levels of thermal conductivity while reducing wear and increasing electrode life.
Together, our electrode materials and NDB method produce electrodes that have the best possible bond, to deliver improved weld strength and consistency, minimum electrode sticking, and maximum electrode life — optimizing both efficiency and weld quality. Since NDB electrodes have good electric conductance to the shank, the electrodes can be cooled down quickly while conduction is suspended. This avoids electrode burnout while also hastening the shot cycle, for further improvements in productivity.
For die sinker EDM, which requires various compositions, we offer all the standard ratios in small to large sizes with uniform blending throughout the block and superior density to eliminate porosity. Our powder metallurgy expertise produces materials that are easily machined to your final shape, whether for your die sinker application or your spot welding configuration.
Offering a Unique Composition in Electrode Materials
We even have a new proprietary composition that has been specifically formulated for exceptional speed and wear performance for the electrical discharge machining of carbides. This exclusive new material grade is C-EDM, and it outperforms even our own standard copper tungsten electrodes. C-EDM has been shown to have a 52% longer life and cuts at 25% faster speeds, resulting in significant manufacturing advantages.
Copper Tungsten Electrodes
A best-selling product for resistance spot welding and die sinker EDM applications, Metal Cutting’s copper tungsten electrodes resist cracking and offer superior performance. Our unique non-defective bonding (NDB) technology creates a copper tungsten electrode that provides the desired levels of thermal conductivity while reducing wear and increasing electrode life. The result is optimal productivity and weld quality for your electrode applications.
Silver Tungsten Electrodes
Our high-performance electrodes for high-speed, automated welding applications include silver tungsten electrodes made from a complex alloy that exhibits the desired levels of thermal and electrical conductivity and moderate hardness at high temperature.
Pure Tungsten Electrodes
Our pure tungsten electrodes exhibit superior characteristics at high temperature and deliver the exceptional performance required for resistance spot welding of non-ferrous metals. Our unique non-defective bonding (NDB) technology creates an electrode that provides the desired levels of thermal conductivity while reducing wear and increasing electrode life, resulting in maximum productivity and exceptional weld quality for your tungsten electrode applications.