DATA SHEET

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RECOMMENDED ELECTRODE MATERIALS 2.

3.
Metallurgical properties
Nature of resultant weld or alloy
The process of resistance welding makes it possible to join most metals, similar or dissim- 4. Weld strength
ilar. Bonds of adequate strength are obtainable for an extremely wide range of applications. 5. Relative accuracy in control of welding conditions necessary
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. The weldability of metals as shown in the chart applies only when conventional spot weld-
ing methods are used on similar thicknesses of material. However, many metal combina-
The weldability of two materials as expressed in the following chart has been derived after tions which are listed as having a “poor weldability” may be satisfactorily joined by using a
careful laboratory study and field survey of many factors which influence the welding or special setup or procedure.
resultant weld of the metals. The factors include:
There is a CMW® Alloy for each specific welding application. Experienced CMW engineers
1. Thermal and electrical conductivity will provide assistance with special problems.

Electrode Materials For SPOT WELDING Similar and Dissimilar Metals

Galva-
Tungsten Cad- nized Phos- Alu- C. P.
Mag- Nickel Stainless Chrome Terne Tin Scaly C. R. Silicon Nickel Cupro Brass Brass Alu-
Molyb- Nickel mium Steel Steel phor Copper minum Tita-
nesium Alloys Steel Steel Zn. Plate Plate Plate Steel Bronze Silver Nickel Yellow Red minum
denum Plate Bronze Alloys nium
II
Commercially Pure A III
Titanium II
III 1

Aluminum C I E II E II H I H II E I D I D I D I E II D II D II D II E II H V C I C I
1 2 2 23 3
2S-3S I 5 I 5 I 3 I 4 I 8 I 394 I 394 I 394 I 394 I 34 I 25 I 25 I 5 I 2 I 2 I 1 I 1
Aluminum Alloys C I E II E II H I H II E I
II D I D I D I E II D II D II D II E II E V D 1
Duralumin
52S-17S-24S I 1 5 I 2 I 2 3 I 243 I 3 8 I 34
9 I 394 I 394 I 394 I 34 I 25 I 25 I 6 I 2 I 2 I 1
H II H I E II E II H I H II H I
II H I H I H I H II D II D II D II D II D II E II K V
Copper—Pure
V 3 V 5 V V 3 6 V 243 V 3 4 V 39 V 394 V 394 V 394 V 34 V 56 V 56 V 56 D 56 V 6 V 6 V 2
Brass—Red H I D II D II H II H II H I
II H I H 1
II H I H II D II D II D II D II D II E II
5-25% Zinc II 5 V 6 V 6 V V V V 6 V 6 V 6 II 3 4 V 6 V 6 V 6 V II II 5 6
I
Brass—Yellow E I D II D II H II H II E II E I E I II E I E II C II C II C II C II C II
25-40% Zinc II 5 IV 6 II 6 IV IV IV 6 IV 6 IV 6 IV 6 IV 3 4 IV 1 IV 1 IV 1 IV 1 II 1
D I C II C VI E II I E II E I
II E I E I
II E I H I
II E II C II C II C II B II
Cupro-Nickel
II 2 5 II II II 2 II 2 8 II 2 II 2 II 2 II 2 II 7 II 3 II 1 II 1 II II 1
D I C II C VI E II I E II E I
II E I E I
II E I H I
II E II C II C II B II
Nickel Silver
II 2 5 II II II 2 II 2 8 II 2 II 2 II 2 II 2 II 7 II 3 II 1 II 1 II 1
D I C II D II E II I E II E I
II E I E I
II E I H I
II D II C II B II
Silicon Bronze
II 2 5 II II II II 8 II II II II II 7 II 3 II 1 II 1
Phosphor Bronze E I D II D II E II I E II E I
II E I E I
II E I H I
II D II B II
Grades A, C, & D II 2 5 II II II II 8 II II II II II 7 II 3 II 1
C. R. Steel D II D II D II B II B II C II C I B I
II C I E I
II A II
H. R. Steel—Clean II 3 II 3 II 3 III II 8 II II II 6 II II 7
II 1
Scaly H II D II I D II D II D I D I
II D I E l
II
H. R. Steel I
II 3 7
I
II 7 I II 7 8 I II 7 I
II 6 7
I
II 6 7
I
II 6 7
I
II 7

E II E I D I D II C II I C II D I
II C I D I
II D I
Tin Plate
I 9 I 59 I 39 I 9 I I 8 I 9 I 69 I 69 I 69
E II E I D I D II C II C II C I
II C I C I
Terne Plate I
II 9 I 5 9 I 3
I 9 I I 8 I I 6 I 6
WELDABILITY ELECTRODES
Galvanized Steel E II E I D II D II C II C II C I C I II As a basis for comparison cold I - CMW® 28
Zinc Plate I 9 I II 5 9 I II 3 II 9 I I 8 9 I 9 I II 9 rolled (mild) steel has been II - CMW® 3
chosen and its weldability BLOCK INTERPRETATION III - CMW® 100
E II E I D I D II C II C II C I designated as “excellent.” IV - ELKONITE® 10W3
Cadmium Plate A - Excellent E - Poor V - ELKON® 100M*
I 9 I 5 I 3 I 9 I I 8 I 9 B - Very Good H - Very Poor WELD- ELECTRODE VI - ELKONITE® 1W3 or TC-5
III C - Good K - Impractical ABILITY AGAINST
DII D II D II B II B II D - Fair
*ELKON® 100 W may be substituted.
Chrome Plate ELKONITE® 10W3 or TC-10 may be
II 8 II 8 II 8 II 8
II 8 SPECIAL interchanged.
ELECTRODE
INFORMA- Electrode materials in circles are
Stainless Steel DII D II D III A IIIII ELECTRODES AGAINST
TION second choice.
III 1 I - CMW® 28
18-8 Type I 25 II II
I II
II - CMW® 3 SPECIAL INFORMATION
D II C II B II III - CMW® 100 1. Good weld strength.
Nickel IV - ELKONITE® 10W3 2. May be welded under special conditions.
Grade A II 2 5 II 1 II 1 3. Low weld strength.
V - ELKON® 100M*
VI - ELKONITE® 1W3 or TC-5 4. No actual weld nugget occurs, a “stick” is
Nickel Alloys D II B II obtained.
Monel Nichrome *ELKON® 100 W may be substituted. 5. Welding conditions must be accurately
(High Res.) II 2 5 II 1 ELKONITE® 10W3 or TC-10 may be controlled.
interchanged. 6. Keep electrode clean to prevent sticking
D I to the work.
Magnesium Electrode materials in circles are 7. Good practice recommends cleaning
Alloys I 15 second choice. steel before welding.
8. Use one flat tip to minimize distortion or
D II discoloration.
Molybdenum 9. Coating may dissolve in other metals or
Tungsten II 2 5 burn away.

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