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.
Choice of Three Copper Tungsten Electrode Compositions
Our three types of copper tungsten electrodes utilize complex alloys that bring together the physical properties of both materials. Our C10B2 electrode has a weight ratio of 10% copper and 90% tungsten, with a specific gravity of 16.8 and hardness of 330 HV. Based on the International Annealed Copper Standard (IACS), this product has an electrical conductivity of 30%; its electrical resistivity is 5.7 x10^-8^ Ωm. Our C30A2 electrode, which is 30% copper and 70% tungsten, has a specific gravity of 14.2, hardness 225 HV, electrical conductivity of 48%, and electrical resistivity of 3.5 x10^-8^ Ωm. Our 50-50 copper tungsten electrode, C50A2, is specific gravity 12.1, hardness 160 HV, electrical conductivity 63%, and electrical resistivity 2.7 x10^-8^ Ωm. (In comparison, a reference material of chromium copper that is 1% copper has a specific gravity of 8.9, hardness 150 HV, electrical conductivity 80%, and electrical resistivity 2.1 x10^-8^ Ωm.)
Smart Design Means Better Welds and Longer Electrode Life
Compared with electrodes using alloys such as chromium copper, testing shows that our copper tungsten electrodes exhibit excellent hardness at high temperature and minimal alloy formation. The results are improved performance without deformation of the electrode or adhesion to the workpiece.
Our copper tungsten electrode design and construction not only utilizes the proper composition and correct tip and shank profiles, but also take advantage of our NDB bonding method in electrode manufacturing, to ensure high thermal conductivity and stable bond quality. As compared with conventional brazing and press fitting, this NBD process creates a bonding area ratio of almost 100%. This high-quality bonding results in electrodes that offer superior cooling performance after the welding stops, which in turn increases shot cycles and production efficiency. Depending on welding conditions, our NDB method results in electrodes that can achieve up to a ten-fold increase in electrode life.
Wide Range of Automated Welding Applications
Thanks to a smart design based on our extensive expertise in tungsten and its alloys, our high-performance copper tungsten electrodes are suited to a wide range of high-speed, automated welding operations. For brazing copper and copper alloys, our copper tungsten electrodes offer excellent electrode heat balance for applications such as high-speed spot welding of wire harnesses for use in motors, automobiles, and anywhere complex or simple wire harnesses are used. Other applications include line switches for battery packs, as well as electrical components for manufacturing lines of circuit breakers and electrical switches. In addition to being used on copper wire and terminals, our electrodes are used in manufacturing lithium ion batteries and nickel hydrogen batteries, as well as in the welding of battery tubs.