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to order by telephone, call toll free: 866.res.weld (737.9353) features r e s i s t a n c e w e l d i n g p r o d u c t s to shop online, visit us at: www.rwelectrodes.com
1 resistance welding products the little tuffaloy man is no w sev enty years old. it was in 1937 that welding sales & engineering company of detr oit introduced a new line of r esistance welding allo ys tradenamed tuffaloy. what began as just a part of a general line of welding equipment soon became their main business, as electrode holders and other resistance w elding accessories were added to the tuffaloy product line. today this now-familiar name represents the most innovative and r espected resistance welding allo y and accessory company in the field. e ven a catalog as comprehensive as this one does not fully show everything tuffaloy is capable of supplying. we have the ability to answer needs that we have yet to hear about. so, if you don find the answers in these pages, tell us what youre looking for. let us work with you in finding solutions. call your tuffaloy distributor or tuffaloy customer services at 1-800-521-3722 or 864-879-0763 . (fax: 864-877-2212 ) visit our internet site at: http://www.tuffaloy.com st andard electronics rwma straight tips 2 tuffcap caps and shanks 5 standard bent electrodes 8 miscellaneous electrodes 11 back up electrodes 12 threaded electrodes 13 swivel tips 14 refractory metal-faced tips 14 welding tip holders cylinder-mounted holders 15 tip adapters 16 multi-spot barrel and clamp 17 straight holders 18 offset holders and welder arms 22 variable-offset holders 24 paddle-type holders 25 platen-mounted holders 28 fast-follow-up holders 39 high pressure welding tips and holders 26 nut and stud welding tips and holders 29 auto nut feeder system components 31 g h series nutwelding heads 32 5 r w stud electrodes 33 multiple welding dual-tip adapters 34 dual-tip holders 35 equa-pr ess holders 36 t riple-tip holders 38 resistance welding alloys welder arms 22 bar stock 40 refractory metals and forgings 41 accessories shunts and jumpers 42 miscellaneous 43 weld force gauges 44 welding data 46 helpful suggestions 49 standard electrodes welding tip holders high pressure welding nut and stud welding resistance welding alloys multiple welding a ccessories tuffaloy table of contents copyright tuffaloy products, 2007, 2009
r wma class 1 rwma class 2 tuffaloy standard straight tips straight tips from tuffaloy are distinguished for t heir high conductivity and resistance to deformation, which are the two major requirements of resistance welding tips. modern manufacturing methods and constant scientific quality control make the difference, starting with the alloying of pure copper, through bar extrusion, and the conversion of this high-quality bar stock into welding tips. tuffaloy ensures conformity to all standard dimensions. before shipment, all tips must pass inspection by gage for uniform length, taper, and outline of point. c 1/2 1/2 b e e a f d f d b a acd e f overall w eiding gauging water hole water hole length face dia. dia. depth dia. 1-1/8 a-1708 131-1708 a-2708 132-2708 1-1/8 a-1710 131-1710 a-2710 132-2710 1-1/8 a-1712 131-1712 a-2712 132-2712 1-1/8 a-1714 131-1714 a-2714 132-2714 1-1/8 a-1716 131-1716 a-2716 132-2716 2 9/32 .731 1-1/4 7/16 2-1/2 9/32 .731 1-3/4 7/16 3 9/32 .731 2-1/4 7/16 3-1/2 9/32 .731 2-3/4 7/16 4 9/32 .731 3-1/4 7/16 2 5/16 .844 1-1/4 1/2 2-1/2 5/16 .844 1-3/4 1/2 3 5/16 .844 2-1/4 1/2 3-1/2 5/16 .844 2-3/4 1/2 4 5/16 .844 3-1/2 1/2 1-1/4 1/4 .613 3/4 3/8 1-1/2 1/4 .613 3/4 3/8 1-3/4 1/4 .613 1 3/8 2 1/4 .613 1-1/4 3/8 2-1/4 1/4 .613 1-1/2 3/8 2-1/2 1/4 .613 1-3/4 3/8 2-3/4 1/4 .613 2 3/8 3 1/4 .613 2-1/4 3/8 3-1/4 1/4 .613 2-1/2 3/8 3-1/2 1/4 .613 2-3/4 3/8 3-3/4 1/4 .613 3 3/8 4 1/4 .613 3-1/4 3/8 1 3/16 .463 1/2 9/32 1-1/4 3/16 .463 3/4 9/32 1-1/2 3/16 .463 1 9/32 1-3/4 3/16 .463 1-1/4 9/32 2 3/16 .463 1-1/2 9/32 2-1/4 3/16 .463 1-3/4 9/32 2-1/2 3/16 .463 2 9/32 2-3/4 3/16 .463 2-1/4 9/32 3 3/16 .463 2-1/2 9/32 3-1/4 3/16 .463 2-3/4 9/32 3-1/2 3/16 .463 3 9/32 3-3/4 3/16 .463 3-1/4 9/32 4 3/16 .463 3-1/2 9/32 1 a-1608 131-1608 a-2608 132-2608 1 a-1610 131-1610 a-2610 132-2610 1 a-1612 131-1612 a-2612 132-2612 1 a-1614 131-1614 a-2614 132-2614 1 a-1616 131-1616 a-2616 132-2616 1/2 a-1505 131-1505 a-2505 132-2505 7/8 a-1506 131-1506 a-2506 132-2506 7/8 a-1507 131-1507 a-2507 132-2507 7/8 a-1508 131-1508 a-2508 132-2508 7/8 a-1509 131-1509 a-2509 132-2509 7/8 a-1510 131-1510 a-2510 132-2510 7/8 a-1511 131-1511 a-2511 132-2511 7/8 a-1512 131-1512 a-2512 132-2512 7/8 a-1513 131-1513 a-2513 132-2513 7/8 a-1514 131-1514 a-2514 132-2514 7/8 a-1515 131-1515 a-2515 132-2515 7/8 a-1516 131-1516 a-2516 132-2516 3/8 a-1404 131-1404 a-2404 132-2404 3/4 a-1405 131-1405 a-2405 132-2405 3/4 a-1406 131-1406 a-2406 132-2406 3/4 a-1407 131-1407 a-2407 132-2407 3/4 a-1408 131-1408 a-2408 132-2408 3/4 a-1409 131-1409 a-2409 132-2409 3/4 a-1410 131-1410 a-2410 132-2410 3/4 a-1411 131-1411 a-2411 132-2411 3/4 a-1412 131-1412 a-2412 132-2412 3/4 a-1413 131-1413 a-2413 132-2413 3/4 a-1414 131-1414 a-2414 132-2414 3/4 a-1415 131-1415 a-2415 132-2415 3/4 a-1416 131-1416 a-2416 132-2416 descrip- part descrip- part tion no. tion no. no. 4 rw taper - 1/2diameter no. 5 rw taper - 5/8diameter no. 6 r w t aper - 3/4diameter no. 7 r w taper - 7/8diameter b nose length a pointed nose rw ma class 1 rwma class 2 3/8 b-1708 133-1708 b-2708 134-2708 3/8 b-1710 133-1710 b-2710 134-2710 3/8 b-1712 133-1712 b-2712 134-2712 3/8 b-1714 133-1714 b-2714 134-2714 3/8 b-1716 133-1716 b-2716 134-2716 3/8 b-1608 133-1608 b-2608 134-2608 3/8 b-1610 133-1610 b-2610 134-2610 3/8 b-1612 133-1612 b-2612 134-2612 3/8 b-1614 133-1614 b-2614 134-2614 3/8 b-1616 133-1616 b-2616 134-2616 3/8 b-1505 133-1505 b-2505 134-2505 3/8 b-1506 133-1506 b-2506 134-2506 3/8 b-1507 133-1507 b-2507 134-2507 3/8 b-1508 133-1508 b-2508 134-2508 3/8 b-1509 133-1509 b-2509 134-2509 3/8 b-1510 133-1510 b-2510 134-2510 3/8 b-1511 133-1511 b-2511 134-2511 3/8 b-1512 133-1512 b-2512 134-2512 3/8 b-1513 133-1513 b-2513 134-2513 3/8 b-1514 133-1514 b-2514 134-2514 3/8 b-1515 133-1515 b-2515 134-2515 3/8 b-1516 133-1516 b-2516 134-2516 1/4 b-1404 133-1404 b-2404 134-2404 1/4 b-1405 133-1405 b-2405 134-2405 1/4 b-1406 133-1406 b-2406 134-2406 1/4 b-1407 133-1407 b-2407 134-2407 1/4 b-1408 133-1408 b-2408 134-2408 1/4 b-1409 133-1409 b-2409 134-2409 1/4 b-1410 133-1410 b-2410 134-2410 1/4 b-1411 133-1411 b-2411 134-2411 1/4 b-1412 133-1412 b-2412 134-2412 1/4 b-1413 133-1413 b-2413 134-2413 1/4 b-1414 133-1414 b-2414 134-2414 1/4 b-1415 133-1415 b-2415 134-2415 1/4 b-1416 133-1416 b-2416 134-2416 descrip- part descrip- part tion no. tion no. b nose length dome nose 2
r wma class 1 rwma class 2 the bright shiny look of tuffaloy tips is the result of a passivation process that eliminates excessive oxidation. it reflects the deep-down quality built into these tips and into all tuffaloy products. only rwma class 1 (tuffaloy 88) and class 2 (tuffaloy 77) tips are listed here. class 3 alloy (tuffaloy 55) tips are also available. for recommended uses of these alloys, see page 46. to order class 3 alloy tips, change description code to indicate it: see ey to description page 4. 3 0? 45? on tips 1-1/4 or less in length c c 1/2 1/2 ee a f d f d a ad e f overall gauging water hole water hole length dia. depth dia. 7/8 c-1708 135-1708 c-2708 136-2708 7/8 c-1710 135-1710 c-2710 136-2710 7/8 c-1712 135-1712 c-2712 136-2712 7/8 c-1714 135-1714 c-2714 136-2714 7/8 c-1716 135-1716 c-2716 136-2716 2 .731 1-1 7/16 2-1/2 .731 1-3/4 7/16 3 .731 2-1/4 7/16 3-1/2 .731 2-3/4 7/16 4 .731 3-1/4 7/16 2 .844 1-1/4 1/2 2-1/2 .844 1-3/4 1/2 3 .844 2-1/4 1/2 3-1/2 .844 2-3/4 1/2 4 .844 3-1/2 1/2 1-1/4 .613 3/4 3/8 1-1/2 .613 3/4 3/8 1-3/4 .613 1 3/8 2 .613 1-1/4 3/8 2-1/4 .613 1-1/2 3/8 2-1/2 .613 1-3/4 3/8 2-3/4 .613 2 3/8 3 .613 2-1/4 3/8 3-1/4 .613 2-1/2 3/8 3-1/2 .613 2-3/4 3/8 3-3/4 .613 3 3/8 4 .613 3-1/4 3/8 1 .463 1/2 9/32 1-1/4 .463 3/4 9/32 1-1/2 .463 1 9/32 1-3/4 .463 1-1/4 9/32 2 .463 1-1/2 9/32 2-1/4 .463 1-3/4 9/32 2-1/2 .463 2 9/32 2-3/4 .463 2-1/4 9/32 3 .463 2-1/2 9/32 3-1/4 .463 2-3/4 9/32 3-1/2 .463 3 9/32 3-3/4 .463 3-1/4 9/32 4 .463 3-1/2 9/32 3/4 c-1608 135-1608 c-2608 136-2608 3/4 c-1610 135-1610 c-2610 136-2610 3/4 c-1612 135-1612 c-2612 136-2612 3/4 c-1614 135-1614 c-2614 136-2614 3/4 c-1616 135-1616 c-2616 136-2616 5/8 c-1505 135-1505 c-2505 136-2505 5/8 c-1506 135-1506 c-2506 136-2506 5/8 c-1507 135-1507 c-2507 136-2507 5/8 c-1508 135-1508 c-2508 136-2508 5/8 c-1509 135-1509 c-2509 136-2509 5/8 c-1510 135-1510 c-2510 136-2510 5/8 c-1511 135-1511 c-2511 136-2511 5/8 c-1512 135-1512 c-2512 136-2512 5/8 c-1513 135-1513 c-2513 136-2513 5/8 c-1514 135-1514 c-2514 136-2514 5/8 c-1515 135-1515 c-2515 136-2515 5/8 c-1516 135-1516 c-2516 136-2516 1/2 c-1404 135-1404 c-2404 136-2404 1/2 c-1405 135-1405 c-2405 136-2405 1/2 c-1406 135-1406 c-2406 136-2406 1/2 c-1407 135-1407 c-2407 136-2407 1/2 c-1408 135-1408 c-2408 136-2408 1/2 c-1409 135-1409 c-2409 136-2409 1/2 c-1410 135-1410 c-2410 136-2410 1/2 c-1411 135-1411 c-2411 136-2411 1/2 c-1412 135-1412 c-2412 136-2412 1/2 c-1413 135-1413 c-2413 136-2413 1/2 c-1414 135-1414 c-2414 136-2414 1/2 c-1415 135-1415 c-2415 136-2415 1/2 c-1416 135-1416 c-2416 136-2416 descrip- part descrip- part tion no. tion no. no. 4 rw taper - 1/2diameter no. 5 rw taper - 5/8diameter no. 6 r w t aper - 3/4diameter no. 7 r w taper - 7/8diameter c w elding face dia. flat nose rw ma class 1 rwma class 2 5/16 d-1708 137-1708 d-2708 138-2708 5/16 d-1710 137-1710 d-2710 138-2710 5/16 d-1712 137-1712 d-2712 138-2712 5/16 d-1714 137-1714 d-2714 138-2714 5/16 d-1716 137-1716 d-2716 138-2716 9/32 d-1608 137-1608 d-2608 138-2608 9/32 d-1610 137-1610 d-2610 138-2610 9/32 d-1612 137-1612 d-2612 138-2612 9/32 c-1614 137-1614 d-2614 138-2614 9/32 d-1616 137-1616 d-2616 138-2616 1/4 d-1505 137-1505 d-2505 138-2505 1/4 d-1506 137-1506 d-2506 138-2506 1/4 d-1507 137-1507 d-2507 138-2507 1/4 d-1508 137-1508 d-2508 138-2508 1/4 d-1509 137-1509 d-2509 138-2509 1/4 d-1510 137-1510 d-2510 138-2510 1/4 d-1511 137-1511 d-2511 138-2511 1/4 d-1512 137-1512 d-2512 138-2512 1/4 d-1513 137-1513 d-2513 138-2513 1/4 d-1514 137-1514 d-2514 138-2514 1/4 d-1515 137-1515 d-2515 138-2515 1/4 d-1516 137-1516 d-2516 138-2516 3/16 d-1404 137-1404 d-2404 138-2404 3/16 d-1405 137-1405 d-2405 138-2405 3/16 d-1406 137-1406 d-2406 138-2406 3/16 d-1407 137-1407 d-2407 138-2407 3/16 d-1408 137-1408 d-2408 138-2408 3/16 d-1409 137-1409 d-2409 138-2409 3/16 d-1410 137-1410 d-2410 138-2410 3/16 d-1411 137-1411 d-2411 138-2411 3/16 d-1412 137-1412 d-2412 138-2412 3/16 d-1413 137-1413 d-2413 138-2413 3/16 d-1414 137-1414 d-2414 138-2414 3/16 d-1415 137-1415 d-2415 138-2415 3/16 d-1416 137-1416 d-2416 138-2416 descrip- part descrip- part tion no. tion no. offset nose c w elding face dia. 3 tuffaloy standard straight tips
r wma class 1 rwma class 2 tuffaloy standard straight tips 45 r c 1/2 1/2 ee a f d f d a ad e f overall gauging water hole water hole length dia. depth dia. 5/16 e-1708 140-1708 e-2708 140-2708 5/16 e-1710 140-1710 e-2710 140-2710 5/16 e-1712 140-1712 e-2712 140-2712 5/16 e-1714 140-1714 e-2714 140-2714 5/16 e-1716 140-1716 e-2716 140-2716 2 .731 1-1/4 7/16 2-1/2 .731 1-3 /4 7/16 3 .731 2-1/4 7/16 3-1/2 .731 2-3/4 7/16 4 .731 3-1/4 7/16 2 .844 1-1/4 1/2 2-1/2 .844 1-3/4 1/2 3 .844 2-1/4 1/2 3-1/2 .844 2-3/4 1/2 4 .844 3-1/2 1/2 1-1/4 .613 3/4 3/8 1-1/2 .613 3/4 3/8 1-3/4 .613 1 3/8 2 .613 1-1/4 3/8 2-1/4 .613 1-1/2 3/8 2-1/2 .613 1-3/4 3/8 2-3/4 .613 2 3/8 3 .613 2-1/4 3/8 3-1/4 .613 2-1/2 3/8 3-1/2 .613 2-3/4 3/8 3-3/4 .613 3 3/8 4 .613 3-1/4 3/8 1 .463 1/2 9/32 1-1/4 .463 3/4 9/32 1-1/2 .463 1 9/32 1-3/4 .463 1-1/4 9/32 2 .463 1-1/2 9/32 2-1/4 .463 1-3/4 9/32 2-1/2 .463 2 9/32 2-3/4 .463 2-1/4 9/32 3 .463 2-1/2 9/32 3-1/4 .463 2-3/4 9/32 3-1/2 .463 3 9/32 3-3/4 .463 3-1/4 9/32 4 .463 3-1/2 9/32 9/32 e-1608 140-1618 e-2608 140-2608 9/32 e 1610 140-1610 e-2610 140-2610 9/32 e-1612 140-1612 e-2612 140-2612 9/32 e-1614 140-1614 e-2614 140-2614 9/32 e-1616 140-1616 e-2616 140-2616 1/4 e-1505 140-1505 e-2505 140-2505 1/4 e-1506 140-1506 e-2506 140-2506 1/4 e-1507 140-1507 e-2507 140-2507 1/4 e-1508 140-1508 e-2508 140-2508 1/4 e-1509 140-1509 e-2509 140-2509 1/4 e-1510 140-1510 e-2510 140-2510 1/4 e-1511 140-1511 e-2511 140-2511 1/4 e-1512 140-1512 e-2512 140-2512 1/4 e-1513 140-1513 e-2513 140-2513 1/4 e-1514 140-1514 e-2514 140-2514 1/4 e-1515 140-1515 e-2515 140-2515 1/4 e-1516 140-1516 e-2516 140-2516 3/16 e-1404 140-1404 e-2404 140-2404 3/16 e-1405 140-1405 e-2405 140-2405 3/16 e-1406 140-1406 e-2406 140-2406 3/16 e-1407 140-1407 e-2407 140-2407 3/16 e-1408 140-1408 e-2408 140-2408 3/16 e-1409 140-1409 e-2409 140-2409 3/16 e-1410 140-1410 e-2410 140-2410 3/16 e-1411 140-1411 e-2411 140-2411 3/16 e-1412 140-1412 e-2412 140-2412 3/16 e-1413 140-1413 e-2413 140-2413 3/16 e-1414 140-1414 e-2414 140-2414 3/16 e-1415 140-1415 e-2415 140-2415 3/16 e-1416 140-1416 e-2416 140-2416 descrip- part descrip- part tion no. tion no. no. 4 rw taper - 1/2diameter no. 5 rw taper - 5/8diameter no. 6 r w t aper - 3/4diameter no. 7 r w taper - 7/8diameter c w elding face dia. truncated cone rw ma class 1 rwma class 2 6 f-1708 141-1708 f 2708 141-2708 6 f-1710 141-1710 f-2710 141-2710 6 f-1712 141-1712 f-2712 141-2712 6 f-1714 141-1714 f-2714 141-2714 6 f-1716 141-1716 f-2716 141-2716 4 f-1608 141-1608 f-2608 141-2608 4 f-1610 141-1610 f-2610 141-2610 4 f-1612 141-1612 f-2612 141-2612 4 f-1614 141-1614 f-2614 141-2614 4 f-1616 141-1616 f-2616 141-2616 2 f-1515 141-1505 f-2505 141-2505 2 f-1506 141-1506 f-2506 141-2506 2 f-1507 141-1507 f-2507 141-2507 2 f-1508 141-1508 f-2508 141-2508 2 f-1509 141-1509 f-2509 141-2509 2 f-1510 141-1510 f-2510 141-2510 2 f-1511 141-1511 f-2511 141-2511 2 f-1512 141-1512 f-2512 141-2512 2 f-1513 141-1513 f-2513 141-2513 2 f-1514 141-1514 f-2514 141-2514 2 f-1515 141-1515 f-2515 141-2515 2 f-1516 141-1516 f-2516 141-2516 2 f-1404 141-1404 f-2404 141-2404 2 f-1405 141-1405 f-2405 141-2405 2 f-1406 141-1406 f-2406 141-2406 2 f-1407 141-1407 f-2407 141-2407 2 f-1408 141-1408 f-2408 141-2408 2 f-1409 141-1409 f-2409 141-2409 2 f-1410 141-1410 f-2410 141-2410 2 f-1411 141-1411 f-2411 141-2411 2 f-1412 141-1412 f-2412 141-2412 2 f-1413 141-1413 f-2413 141-2413 2 f-1414 141-1414 f-2414 141-2414 2 f-1415 141-1415 f-2415 141-2415 2 f-1416 141-1416 f-2416 141-2416 descrip- part descrip- part tion no. tion no. radius faced r nose radius tip size length 4 rw 1/2-in. 5 rw 3/4-in. 6 rw 7/8-in. 7 rw 1-1/8-in. taper engagement key to description nose designation rwma alloy class rw taper no. length, in number of 1/4-in. increments e-2-5-10 4
tuffcap electrodes consist of two pieces: a shank and a replaceable cap. these two-part electrodes can offer major economies, because when the nose geometry is worn out, only the cap needs to be replaced. and it costs far less than a standard one-piece electrode. (a tuffcap shank will normally outlast twenty caps.) also, electrode i nventory can be kept small because all nose designs will fit the same size shank. two types: tuffaloy offers two kinds of tuffcap electrodes. one uses a male cap that fits into the shank. the other has a female cap that fits over the shank. female and male caps are available in the widest range of sizes, alloys, and styles. they are made in both class 1 and class 2 alloy, and in sizes to fit- shanks sized 4 through 7 rw. male caps are more effectively cooled than female caps. all caps are made with the same nose designs in conformance with rwma standards. shanks are made of class 2 alloy, either straight, or bent to provide an offset. shanks other than those cataloged can be special ordered. tuffcap, caps and shanks should be used only in a directly opposed, straight-line manner. they do not work as well as standard electrodes on heavily coated metal such as galv aniz ed or tin-plate. tufftrode-z caps for coated steels to avoid electrode sticking problems common when welding galvanized and aluminized materials, these copper chrome-zirconium alloy caps are offered. they give the same performance as dispersion-strengthened caps but cost far less. they are class 2 caps in mechanical and physical properties. both male and female caps are offered in all the standard nose designs. to avoid mushrooming and brassing problems associated with standard designs, these caps have a self-dressing weld face ring that acts as a control zone. the super nose caps are available in tuffaloys new ?aterial, that eliminates electrode sticking problems common when welding galvanized and aluminized materials. both male and female designs are offered, designed to fit shanks with 5 rw taper. siz e 5 rw straight and offset style shanks holding male type caps with swivel heads. these caps ar e cataloged on pages 6 & 7. male cap type electrode assembly female cap type electrode assembly 5 tuffaloy caps and shanks u.s. patent number 5,155,320 other patents pending ne w! super nose design caps
tuffaloy caps and shanks male caps straight shanks for male caps (class 2*) bent shanks for male caps (class 2*) nose 4 and 5 cap nose 4 and 5 cap shank off- descip- part length set tion no. 2-1/2 1/2 3-1/4 tg-2410-08 162-2410 2-1/2 3/4 3-1/4 tg-2410-12 162-2420 2-1/2 1 3-1/4 tg-2410-16 162-2430 3 1/2 3-3/4 tg-2412-8 162-2450 3 1-1/4 3-3/4 tg-2412-20 162-2460 3-1/4 1 4 tg-2413-16 162-2470 3-1/4 1-1/4 4 tg-2413-20 162-2480 shank assembled descip- part length length tion no. 1-1/4 2 tg-2405 161-2405 1 -1/2 2-1/4 tg-2406 161-2406 1 -3/4 2-1/2 tg-2407 161-2407 2 2-3/4 tg-2408 161-2408 2-1/4 3 tg-2409 161-2409 2 -1/2 3-1/4 tg-2410 161-2410 2 -3/4 3-1/2 tg-2411 161-2411 3 3-3/4 tg-2412 161-2412 3-1/4 4 tg-2413 161-2413 1 -1/4 2 tg-2505 161-2505 1-1/2 2-1/4 tg-2506 161-2506 1-3/4 2-1/2 tg-2507 161-2507 2 2-3/4 tg-2508 161-2508 2 -1/4 3 tg-2509 161-2509 2-1/2 3-1/4 tg-2510 161-2510 2-3/4 3-1/2 tg-2511 161-2511 3 3-3/4 tg-2512 161-2512 3 -1/4 4 tg-2513 161-2513 t aper of adapter shank 1 4rw ta-14 111-0014 2 4rw ta-24 112-0024 3 4rw ta-34 122-1034 1 5rw ta-15 111-0015 1 &2 5rw ta-25z 126-0025 2 5rw ta-25 112-0025 3 5rw ta-35 122-1035 1 6rw ta-16 111-0016 2 6rw ta-26 112-0026 1 7rw ta-17 111-0017 2 7rw ta-27 112-0027 z 4rw ts-24z 127-0024 z 5rw ts-25z 127-0025 1 4rw tb-14 113-0014 2 4rw tb-24 114-0024 1 5rw tb-15 113-0015 2 5rw tb-25 114-0025 1 6rw tb-16 113-0016 2 6rw tb-26 114-0026 1 7rw tb-17 113-0017 2 7rw tb-27 114-0027 1 4rw tc-14 115-0014 2 4rw tc-24 116-0024 3 4rw tc-34 122-3034 1 5rw tc-15 115-0015 2 5rw tc-25 116-0025 3 5rw tc-35 122-3035 1 6rw tc-16 115-0016 2 6rw tc-26 116-0026 1 7rw tc-17 115-0017 2 7rw tc-27 116-0027 1 4rw td-14 117-0014 2 4rw td-24 118-0024 3 4rw td-34 122-4034 1 5rw td-15 117-0015 2 5rw td-25 118-0025 3 5rw td-35 122-4035 1 6rw td-16 117-0016 2 6rw td-26 118-0026 1 7rw td-17 117-0017 2 7rw td-27 118-0027 1 -1/2 2-1/2 tg-2606 161-2606 2 3 tg-2608 161-2608 2-1/2 3-1/2 tg-2610 161-2610 3 4 tg-2612 161-2612 1-1/2 2-1/2 tg-2706 161-2706 2 3 tg-2708 161-2708 2-1/2 3-1/2 tg-2710 161-2710 3 4 tg-2712 161-2712 length 2-1/4 1/4 3 tg-2509-4 162-2505 2-1/2 1/2 3-1/4 tg-2510-8 162-2510 2-1/2 3/4 3-1/4 tg-2510-12 162-2520 2-1/2 1 3-1/4 tg-2510-16 162-2530 3 1/2 3-3/4 tg-2512-8 162-2550 3 1-1/4 3-3/4 tg-2512-20 162-2560 3-1/4 1 4 tg-2513-16 162-2570 3-1/4 1-1/4 4 tg-2513-20 162-2580 other sizes available alloy descrip- part class tion no. p ointed tips shanks 4 rw taper shanks 5 rw taper s hanks 6 rw taper shanks 4 rw taper shanks 5 rw taper shanks 7 r w t aper dome tips flat tips offset tips 6 * class 3 available
female caps straight shanks for female caps (class 2*) bent shanks for female caps (class 2*) nose 4 and 5 cap nose 4 and 5 cap shank off- descrip- item length set tion no. 2-3/4 1/2 3-1/4 tp-2411-08 164-2442 2-3/4 3/4 3-1/4 tp-2411-12 164-2445 2-3/4 1 3-1/4 tp-2411-16 164-2447 3-1/4 1/2 3-3/4 tp-2413-08 164-2465 3-1/4 1-1/4 3-3/4 tp-2413-20 164-2480 3-1/2 1 4 tp-2414-16 164-2490 shank assembled descrip- part length length tion no. 1-1/2 2 tp-2406 163-2406 1 -3/4 2-1/4 tp-2407 163-2407 2 2-1/2 tp-2408 163-2408 2-1/4 2-3/4 tp-2409 163-2409 2-1/2 3 tp-2410 163-2410 2 -3/4 3-1/4 tp-2411 163-2411 3 3-1/2 tp-2412 163-2412 3-1/4 3-3/4 tp-2413 163-2413 3-1/2 4 tp-2414 163-2414 1 -1/2 2 tp-2506 163-2506 1-3/4 2-1/4 tp-2507 163-2507 2 2-1/2 tp-2508 163-2508 2 -1/4 2-3/4 tp-2509 163-2509 2 -1/2 3 tp-2510 163-2510 2-3/4 3-1/4 tp-2511 163-2511 3 3-1/2 tp-2512 163-2512 3 -1/4 3-3/4 tp-2513 163-2513 3 -1/2 4 tp-2514 163-2514 t aper of adapter shank 2 4rw tp-24a 125-0241 2 5rw tp-25a 125-0251 2 6rw tp-26a 125-0261 z4rw tp-24sz 127-0241 z 5rw tp-25sz 127-0251 2 4rw tp-24b 125-0242 2 5rw tp-25b 125-0252 2 6rw tp-26b 125-0262 2 4rw tp-24c 125-0243 2 5rw tp-25c 125-0253 2 6rw tp-26c 125-0263 2 4rw tp-24d 125-0244 2 5rw tp-25d 125-0254 2 6rw tp-26d 125-0264 1-1/2 2 tp-2606 163-2606 2 2 -1/2 tp-2608 163-2608 2-1/2 3 tp-2610 163-2610 3 3-1/2 tp-2612 163-2612 length 2-3/4 1/2 3-1/4 tp-2511-08 164-2542 2-3/4 3/4 3-1/4 tp-2511-12 164-2545 2-3/4 1 3-1/4 tp-2511-16 164-2547 3-1/4 1/2 3-3/4 tp-2513-08 164-2565 3-1/2 1 4 tp-2513-16 164-2570 3-1/4 1-1/4 3-3/4 tp-2513-20 164-2580 other sizes available alloy descrip- part class tion no. p ointed tips s hanks 4 rw taper shanks 5 rw taper shanks 6 rw taper shanks 4 rw taper shanks 5 rw taper dome tips flat tips offset tips for improved cooling, female shanks are drilled through (to put water in contact with cap). shanks may be ordered with a blind water hole, upon request. 7 tuffaloy caps and shanks * class 3 available .840 .840 .840 9/32
tuffaloy bent tips double-bent, additional nose designs example: fb-1438-16-t f = cold-formed, double-bend t ips x = nose t ype a b c d y = r wm a a llo y class 1 = class 1 2 = class 2 z = r w taper number 4 =4r w 5 = 5rw l = l ength in inches r efer to table for av ailability d = additional l ength in 16ths o = offset in 16ths r efer to table for av ailability t = w ith water tubes key to description fx-yzld-o a pointed nose flat nose offset nose b dome nose double-bend, with standard nose designs t hese standard cold-formed tips are bent from straight tips (some after added machining) and have the same hardness and conductivity. they outlast, many times over, the old cast and forged tips of similar geometry, which are impossible to cool adequately. the table shows a wide range of tips generally available from stock. for sizes not shown, refer to the diagrams and description key at the bottom of the page, and order what you need. all measurements will be accurate. however, over-all length, in 1/8-in. multiples, will be held to within 1/16-in. tapers, water holes, and nose designs are the same as the standard straight tips in this catalog. water tubes can be furnished. standard nose designs other than those shown here may be furnished on short order. follow the ey to description using a for dome nose, for flat nose, for truncated cone, and for radius nose. 8 taper no. length offset 4 rw 5 rw f a pointed nose fd offset nose f a pointed nose fd offset nose descrip- item descrip- item descrip- item descrip- item tion no. tion no. tion no. tion no. 1-1/2 7/1 6 f a-2317-8 167-0060 2-3/16 1 fd-2423-16 167-2080 2-1/4 1/2 fa-1424-8 165-0100 fa-2424-8 167-0100 2-1/4 3/4 fa-2424-12 167-0120 2-3/8 3/8 fa-1426-6 165-0160 fa-2426-6 167-0160 2-3/8 3/4 fa-2426-12 167-0180 2-3/8 1-1/4 fa-1426-20 165-0200 fd-1426-20 165-2200 fa-2426-20 167-0200 fd-2426-20 167-2200 2-1/2 1/2 fa-2428-8 167-0240 2-1/2 1 fa-1428-16 165-0280 fd-1428-16 165-2280 fa-2428-16 167-0280 fd-2428-16 167-2280 2-5/8 3/4 fa-14210-12 165-0320 fa-24210-12 167-0320 fd-24210-12 167-2320 2-3/4 1/2 fa-14212-8 165-0360 fa-24212-8 167-0360 fd-24212-8 167-2360 2-3/4 1 fa-24212-16 167-0400 2-3/4 1-1/4 fa-24212-20 167-0420 2-7/8 3/4 fa-24214-12 167-0430 2-7/8 1-1/4 fa-14214-20 165-0460 fa-24214-20 167-0460 3 1 fa-1430-16 165-0520 fa-2430-16 167-0520 3-3/8 1-1/4 fa-2436-20 167-0580 3-1/2 1 fa-2438-16 167-0620 2-1/4 1/2 fd-2524-8 167-3100 2-1/4 1-1/4 fd-1524-20 165-3140 fd-2524-20 167-3140 2-3/8 3/8 fa-1526-6 165-1160 fa-2526-6 167-1160 fd-2526-6 167-3160 2-3/8 3/4 fd-1526-12 165-3180 fa-2526-12 167-1180 fd-2526-12 167-3180 2-7/16 1-5/16 2-1/2 1/2 fa-1528-8 165-1240 fa-2528-8 167-1240 2-1/2 1 fa-2528-16 167-1280 2-3/4 1/2 fa-15212-8 165-1360 fd-15212-8 165-3360 fa-25212-8 167-1360 fd-25212-8 167-3360 2-3/4 3/4 fa-25212-12 167-1380 2-3/4 1 fa-15212-16 165-1400 fd-15212-16 165-3400 fa-25212-16 167-1400 fd-25212-16 167-3400 2-7/8 1 fa-25214-16 167-1440 2-7/8 1-1/4 fa-15214-20 165-1460 fa-25214-20 167-1460 3 1/2 fa-1530-8 165-1480 fa-2530-8 167-1480 fd-2530-8 167-3480 3 3/4 fa-2530-12 167-1500 3 1 fa-2530-28 167-1540 fd-2530-16 167-3520 3-1/4 1 fa-1534-16 165-1560 fa-2534-16 167-1560 3-3/8 3/8 fd-1536-6 165-3570 3-3/8 1-1/4 fa-1536-20 165-1580 fd-1536-20 165-3580 fa-2536-20 167-1580 fd-2536-20 167-3580 3-1/2 1/2 fa-1538-8 165-1600 fa-2538-8 167-1600 3-1/2 1 fa-2538-16 167-1620 fd-2538-16 167-3620 cl ass i cl ass 2
a pointed nose offset nose fa-14214-20 fa-15214-20 fa-24214-20 fa-25214-20 fd-15212-16 fd-25212-16 fd-15212-8 fd-24212-8 fd-25212-8 fd-24210-12 fa-15212-16 fa-25212-16 fa-1430-16 fa-2430-16 fa-1426-20 fa-2426-20 fa-1426-6 fa-1526-6 fa-2426-6 fa-2526-6 fa-1528-8 fa-2428-8 fa-2528-8 fa-1428-16 fa-2428-16 fa-2528-16 fa-14212-8 fa-15212-8 fa-24212-8 fa-25212-8 fd-1524-20 fd-2524-20 fd-2526-6 fd-1526-12 fd-2526-12 fd-1426-20 fd-2426-20 fd-1428-16 fd-2428-16 fd-1536-20 fd-2536-20 fd-2538-16 fa-1536-20 fa-2436-20 fa-2436-20 fa-1538-8 fa-2538-8 9 tuffaloy bent tips
tuffaloy bent tips single-bend tips miscellaneous tips fp-2532-10 part no. 167-5540 fp-2428-9.5 part no. 167-4260 fp-2523-7 part no. 167-5060 fp-2527-15 part no. 167-5220 fp-2423-7 part no. 167-5055 fp-2430-8 part no. 167-5065 fp-2530-8 part no. 167-5070 se-4268 part no. 170-4268 se-4269 part no. 170-4269 se-4270 part no. 170-4270 se-4273 part no. 170-4273 se-4274 part no. 170-4274 se-4275 part no. 170-4275 se-4276-1 part no. 170-4276-1 se-4276 part no. 170-4276 se-4271 part no. 170-4271 se-4272 part no. 170-4272 cold-formed tips with a single bend have standard pointed-nose design. other single-bend tips with flat noses (below) or other special designed noses and configur ations ar e av ailable on special or der . these ar e of class 2 alloy; class i alloy can also be ordered. double bend and flattened tips are made from bar stock. these are some of the standard designs available, but special designs can also be made. these are of class 2 alloy; class i allo y can also be or dered. 10
se-4284 (short water hole) part no. 170-4284 se-4285 part no. 170-4285 se-4286 part no. 170-4286 se-4287 part no. 170-4287 se-4282 part no. 170-4282 se-4277 part no. 170-4277 se-4278 part no. 170-4278 se-4279 part no. 170-4279 se-4280 part no. 170-4280 se-4281 part no. 170-4281 se-4283 part no. 170-4283 se-4288 part no. 170-4288 these standard bent tips are in addition to those shown on page 9. t hey are of class 2 alloy; other alloys can also be ordered. 11 tuffaloy miscellaneous tips
alloy taper face descrip- part class no. tion no. 2 5rw 1 220 186-0220 2 4r w 1/2 221 186-0221 2 4rw 1 223 186-0223 2 5rw 1 224 186-0224 2 5rw 1 225 186-0225 2 5rw 2 226 186-0226 2 4rw 2 227 186-0227 2 5rw 1-1/2 228 186-0228 2 4rw 1-1/2 229 186-0229 tuffaloy miscellaneous tips rectangul ar f ace these tips ar e all machined from bar stock. special designs can be made to order. additional back up electrodes with copper t ungsten facings Csee page 32 these straight tips have welding faces angled 30 alloy taper face descrip- part class no. tion no. 2 4rw 7/8 301 186-0301 1 4r w 7/8 302 186-0302 2 5rw 7/8 303 186-0303 1 5rw 7/8 304 186-0304 2 4rw 7/8 305 186-0305 1 4rw 7/8 306 186-0306 2 5rw 7/8 307 186-0307 1 5rw 7/8 308 186-0308 2 4rw 1 309 186-0309 1 4rw 1 310 186-0310 2 5rw 1 311 186-0311 1 5rw 1 312 186-0312 2 5rw 1-1/4 313 186-0313 2 5rw 1-1/2 315 186-0315 2 5rw 1 316 186-0316 round face a lloy taper length descrip- part c lass no. tion no. 2 4rw 3/8 n-15 186-0015 2 4r w 3/4 n-16 186-0016 2 5rw 3/8 n-27 186-0027 2 5rw 3/4 n-28 186-0028 alloy taper length descrip- part class no. tion no. 2 4rw 2 h-2408-30 145-2408 2 4r w 3 h-2412-30 145-2412 2 4rw 4 h-2416-30 145-2416 2 5rw 2 h-2508-30 145-2508 2 5rw 3 h-2512-30 145-2512 2 5rw 4 h-2516-30 145-2516 * * * *311, 313 and 316 available with copper tungsten face. see pg. 32 se-4535 part no. 186-0520 220 221 thr u 224 226 thr u 229 301 thru 304 305 thru 315 316 n-15 thru n-28 225 se-4089-4 part no. 170-4090 se-4089-5 part no. 170-4089 5rw: c-507-5, part no. 186-0507 4rw: c-507-4, part no. 186-0508 12 ba ck up electrodes 5/8
ab c overall tip male description part no. length dia. (hex) thread 2 1 5/8-11 5100-11-c 187-5100-11 1 5/8-18 5100-18-c 187-5100-18 1 3/4-11 5100-10-c 187-5100-10 1-1/4 3/4-10 5125-10-c 187-5125-10 flat electrodes ab c overall tip male description part no. length dia. (hex) thread 2 1 5/8-11 5100-11-e 188-5100-11 1 5/8-18 5100-18-e 188-5100-18 1 3/4-10 5100-10-e 188-5100-10 1-1/4 3/4-10 5125-10-e 188-5125-10 trunca ted electrodes ab c overall tip male description part no. length dia. (hex) thread 3/4 5/8 7/16-14 5062-14-c 187-5062-14 3/4 5/8 3/8-16 5062-16-c 187-5062-16 ?ose electr odes ab c overall tip male description part no. length dia. (hex) thread 3/4 5/8 7/16-14 5062-14-e 188-5062-14 ?ose electrodes 13 tuffaloy threaded tips t uffaloy threaded electrodes are class 2 alloy. other materials are available.
face s-series os-series osh-series ss-series dia. descrip- part descrip. part descrip- part descrip- part f tion no. tion no. tion no. tion no. 7/8 s-248 182-0248 5 -ct* 1 s-249 182-0249 1-1/4 s-250 182-0250 7/8 s-348 182-0348 os-348 182-1348 4 rw 1 s-350 182-0350 os-350 182-1350 1-1/4 s-351 182-0351 os-351 182-1351 7 /8 s-349 182-0349 os-349 182-1349 1 s-353 182-0353 os-353 182-1353 osh-353 182-2353 ss-353 182-3353 5 rw 1-1/4 s-354 182-0354 os-354 182-1354 osh-354 182-2354 ss-354 182-3354 1-1/2 osh-356 182-2356 2 osh-358 182-2358 7rw 2-1/2 3360 182-3360 nose taper facing alloy dimensions descrip- part type no. class a b tion no. 4rw 14 3/16 3/8 a-2408-100m 185-0120 4rw 13 3/16 3/8 a-2408-100w 185-0130 pointed 5rw 11 1/4 3/8 a-2508-10w 185-0150 5rw 14 1/4 3/8 a-2508-100m 185-0160 5rw 13 1/4 3/8 a-2508-100w 185-0170 4rw 11 1/2 1/4 b-2408-10w 185-1110 dome 5rw 11 5/8 1/4 b-2508-10w 185-1120 5rw 13 5/8 1/4 b-2508-100w 185-1170 4rw 11 1/2 1/4 c-2408-10w 185-1210 4rw 14 1/2 1/4 c-2408-100m 185-1220 flat 4rw 13 1/2 1/4 c-2408-100w 185-1230 5rw 11 5/8 1/4 c-2508-10w 185-1250 5rw 14 5/8 1/4 c-2508-100m 185-1260 5rw 13 5/8 1/4 c-2508-100w 185-1270 tuffaloy swivel tips tuffaloy refractory metal-faced tips swivel tips have ball-jointed s wivel heads to compensate for minor misalignment, and to eliminate marking of the work surface. they are all machined from class 2 alloy b ar stock. the s-and ss- series tip water hole does not reach the head. in the os and osh models, the water does contact the head, and o-rings are used to seal it. in the ss series a spring is used to keep pressure on head for better positioning. class 1 and class 3 heads are also av ailable. *w ill fit tuffcap adapter shanks having no . 5 r w tapers, as shown on page 6. note: standard swivel tilt is appro ximately 18 a 25 swivel is av ailable on request. add suffix s to abo ve part number. the tuffaloy copper-tungsten, tungsten and molybdenum-faced tips listed here withstand gr eater heat and pressure, at the expense of some conductivity. besides being used for spot welding high resistance base metals, they are useful in achieving eat balancewhen welding dissimilar metals. (the higher resistance electrode is used against the lower resistance, or thinner, member, to help contain the heat generated.) they have the same diameters and tapers as the standard straight tips in this catalog. bodies are of class 2 alloy. lengths other than those shown can be ordered. taper no. pointed nose dome nose fla t nose s-series* ( tuffcap design) s-series os-series osh-series ss-series 14 2 f
these standard-tip holders are mounted directly to a ir or hydraulic cylinder pistons. they are ideal for assembling special multi-head resistance welding equipment. current and coolant water are brought to each of the holders separately. electrode adapters for the tip diameter being used and in lengths to suit your set-up are ordered separately: see page 16. water tubes, for carrying water into the tip, should also be ordered separately. tuffaloy offers both straight and offset holders for cylinder mounting. clamps, hose connections, water tubes and adaptors are not included. order separately. offset holders offset holders are offered in eight offset sizes, from 1/8 to 1 inch. the standard models have a 1/2-npt adapter socket, to hold adapters for 4 & 5rw tips. ordering a 3/4-npt socket will permit adapters for 6 & 7rw tips to be used. to determine distance adapter sticks out from holder, deduct 1/2-in from length of adapter selected. water tubes 1/2-in. longer than adapter will install appr o ximately flush with adapter face. for 7/8 straight-thread adapters use suffix /8--4 n.f.example: 194-1588-7/8-14 nf. for 4rw use for 5rw, 6rw or 7rw use descrip- part descrip- part tion no. tion no. 3/4 301-.7 194-3107 312-.7 194-3207 1 301-1.0 194-3110 312-1.0 194-3210 1-1/4 301-1.2 194-3112 312-1.2 194-3212 1-1/2 301-1.5 194-3115 312-1.5 194-3215 1-3/4 301-1.7 194-3117 312-1.7 194-3217 2 301-2.0 194-3120 312.2.0 194-3220 2-1/2 301-2.5 194-3125 312-2.5 194-3225 3 301-3.0 194-3130 312-3.0 194-3230 3-1/2 301-3.5 194-3135 312-3.5 194-3235 4 301-4.0 194-3140 312-4.0 194-3240 4-1/2 301-4.5 194-3145 312-4.5 194-3245 offset holders stationary water tubes 4 & 5 rw 6 & 7rw offset width part no. part no. (inches) (inches) 1/2pipe 3/4pipe 1.0 2.5 194-1588 194-1598 0.88 2.5 194-1587 0.75 2.31 194-1586 194-1596 0.62 2.18 194-1585 0.50 2.06 194-1584 194-1594 0.38 1.94 194-1583 0.25 1.81 194-1582 0.12 1.68 194-1581 for 4 & 5 rw tips for 6 or 7 rw tips stationary water tubes length order clamp separately holder clamp 101-2: part no. 194-2040 1/4 ntp hose connection 8241: part no. 195-8241 15 tuffaloy cylinder-mounted holders
abcde pipe thread taper body body over-all description part number or taper socket size length length 1/4 7/8 ad-124-.8 190-1408 3/8 1 ad-124-1.0 190-1410 5/8 1-1/4 ad-124-1.2 190-1412 7/8 1-1/2 ad-124-1.5 190-1415 1-1/8 1-3/4 ad-124-1.7 190-1417 1-3/8 2 ad-124-2.0 190-1420 1/2-14 4rw 1hex 1-5/8 2-1/4 ad-124-2.2* npt 1-7/8 2-1/2 ad-124-2.5 190-1425 2-1/8 2-3/4 ad-124-2.7* 2-3/8 3 ad-124-3.0 190-1430 2-5/8 3-1/4 ad-124-3.2* 2-7/8 3-1/2 ad-124-3.5 190-1435 3-1/8 3-3/4 ad-124-3.7* 3-3/8 4 ad-124-4.0 190-1440 4-3/8 5 ad-124-5.0* 1/4 7/8 ad-125-.8 190-1508 3/8 1 ad-125-1.0 190-1510 5/8 1-1/4 ad-125-1.2 190-1512 7/8 1-1/2 ad-125-15 190-1515 1 1-5/8 ad-125-1.6* 1-1/8 1-3/4 ad-125-1.7 190-1517 1-3/8 2 ad-125-2.0 190-1520 1/2-14 5rw 1hex 1-5/8 2-1/4 ad-125-2.2* npt 1-7/8 2-1 /2 ad-125-2.5 190-1525 2-1/8 2-3/4 ad-125-2.7* 2-3/8 3 ad-125-3.0 190-1530 2-5/8 3-1/4 ad-125-3.2* 2-7/8 3-1/2 ad-125-3.5 190-1535 3-1/8 3-3/4 ad-125-3.7* 3-3/8 4 ad-125-4.0 190-1540 3-7/8 4-1/2 ad-125-4.5 190-1545 1/4 7/8 ad-584-.8 190-2408 5/8-14 4rw 1hex 3/8 1 ad-584-1.0 npt 7/8 1-1/2 ad-584-1.5* 1-3/8 2 ad-584-2.0* 1/4 7/8 ad-585-.8 190-2508 3/8 1 ad-585-1.0* 190-2510 5/8 1-1/4 ad-585-1.2 190-2512 5/8-14 5rw 1hex 7/8 1-1/2 ad-585-1.5 190-2515 npt 1-1/8 1-3/4 ad-585-1.7 190-2517 1 -3/8 2 ad-585-2.0* 1 -7/8 2-1/2 ad-585-2.5* 2 -3/8 3 ad-585-3.0* 3-3/8 4 ad-585-4.0* 3/16 1-1/8 ad-345-1.1* 7/16 1-3/8 ad-345-1.3* 9/16 1-1/2 ad-345-1.5 190-3515 13/16 1-3/4 ad-345-1.7 190-3517 3/4-14 5rw 1.25 hex 1-1/16 2 ad-345-2.0 190-3520 npt 1-9/16 2-1/2 ad-345-2.5 190-3525 2-1/16 3 ad-345-3.0 190-3530 2-9/16 3-1/2 ad-345-3.5 190-3535 3-1/16 4 ad-345-4.0 190-3540 4-1/16 5 ad-345-5.0 190-3550 5/16 1-1/4 ad-346-1.2* 7/16 1-3/8 ad-346-1.3 190-3613 9/16 1-1/2 ad-346-1.5 190-3615 1-1/16 2 ad-346-2.0 190-3620 3/4-14 6rw 1.25 hex 1-9/16 2-1/2 ad-346-2.5 190-3625 npt 1-13/16 2-3/4 ad-346-2.7* 2-1/16 3 ad-346-3.0 190-3630 2-9/16 3-1/2 ad-346-3.5 190-3635 3-1/16 4 ad-346-4.0 190-3640 3-9/16 4-1/2 ad-346-4.5 190-3645 4-1/16 5 ad-346-5.0 190-3650 9/16 1-1/2 ad-347-1.5 190-3715 1-1/16 2 ad-347-2.0 190-3720 1-9/16 2-1/2 ad-347-2.5 190-3725 3/4-14 7rw 1.25 hex 2-1/16 3 ad-347-3.0 190-3730 npt 2-9/16 3-1/2 ad-347-3.5 190-3735 3-1/16 4 ad-347-4.0 190-3740 3-9/16 4-1/2 ad-347-4.5 190-3745 4-1/16 5 ad-347-5.0 190-3750 1 2 ad-45-2 190-4520 4rw 5rw 1hex 2 3 ad-45-3 190-4530 3 4 ad-45-4 190-4540 1/4 1-1/8 ad-54-1 190-5410 1 2 ad-54-2 190-5420 5rw 4rw 7/8 hex 1-1/2 2-1/2 ad-54-2.5* 2 3 ad-54-3 190-5430 3 4 ad-54-4 190-5440 1 2 ad-55-2 190-5520 1-1/2 2-1/2 ad-55-2.5 190-5525 5rw 5rw 7/8 hex 2 3 ad-55-3* 3 4 ad-55-4 190-5540 4 5 ad-55-5 190-5550 5rw 6rw 1hex 1-1/8 2 ad-56-2 190-5620 6r w 4rw 1hex 1/4 1-1/4 ad-64-1 190-6410 6rw 5rw 1hex 1/4 1-1/4 ad-65-1 190-6510 7rw 4rw 1hex 1/4 1-1/2 ad-74-1 190-7410 1/4 1 ad-75-1 190-7510 7rw 5rw 1hex 3/4 2 ad-75-2 190-7520 2-1/4 3-1/2 ad-75-3.5* 2-3/4 4 ad-75-4* tuffaloy threaded electrode adapters are used to provide longer electrode holder life, by providing a changable tip socket in holders having threaded openings. class 2 alloy. other alloys available. * not commonly stocked - other adapters available upon request ad-124-.8, ad-125-.8, ad-584-.8, ad-585-.8, ad-124-1.0, ad-124-4.0, ad-125-1.0, ad-125-4.0, ad-345-1.0, ad-347-4.0, ad-45-2, ad-45-4, ad-54-1, ad-75-2, ad-55-90, for 5 r w t ip, part no. 190-9559 ad-54-90, for 4 r w t ip, part no. 190-9549 a b description part no. 4 rw taper - 7/8-14 nf 3/8 1-1/8 ad-134-1.1 190-3211 1/2 1-1/4 ad-134-1.2 190-3212 5/8 1-3/8 ad-134-1.3 190-3213 3/4 1-1/2 ad-134-1.5 190-3215 1 1-3/4 ad-134-1.7 190-3217 1-1/4 2 ad-134-2.0 190-3220 1-1/2 2-1/4 ad-134-2.2 190-3222 1-3/4 2-1/2 ad-134-2.5 190-3225 2-1/4 3 ad-134-3.0 190-3230 2-3/4 3-1/2 ad-134-3.5 190-3250 5 rw t aper - 7/8-14 nf 3/8 1-1/8 ad-135-1.1 190-3311 1 /2 1-1/4 ad-135-1.2 190-3312 5/8 1-3/8 ad-135-1.3 190-3313 3/4 1-1/2 ad-135-1.5 190-3315 1 1-3/4 ad-135-1.7 190-3317 1-1/4 2 ad-135-2.0 190-3320 1-1/2 2-1/4 ad-135-2.2 190-3322 1-3/4 2-1/2 ad-135-2.5 190-3325 2-1/4 3 ad-135-3.0 190-3330 2-3/4 3-1/2 ad-135-3.5 190-3335 5 rw t aper - 1-12 nf 3/8 1-1/8 ad-105-1.1 190-4311 1/2 1-1/4 ad-105-1.2 190-4312 5/8 1-3/8 ad-105-1.3 190-4313 3/4 1-1/2 ad-105-1.5 190-4315 1 1-3/4 ad-105-1.7 190-4317 1-1/4 2 ad-105-2.0 190-4320 5 r w t aper - 1-12 nf 1-1/2 2-1/4 ad-105-2.2 190-4322 1-3/4 2-1/2 ad-105-2.5 190-4325 2 2-3/4 ad-105-2.7 190-4327 2-1/4 3 ad-105-3.0 190-4330 2-3/4 3-1/2 ad-105-3.5 190-4335 194-2085 1-3/8 d. barrel required for 1-12 nf adapter { { { { { ad-55-30, for 5 rw tip, part no. 190-9553 straight threaded adapters for multi-spot barrel and clamp 16 tuffaloy tip adapters 1.25 hex 1.25 hex 1.25 hex 1.25 hex
holders number of coolant por ts for tip one set two sets clamp sizes descrip- part descrip- part descrip- part tion no. tion no. tion no. 4 & 5 rw 101-a 194-2020 101-b 194-2025 101-2 194-2040 6 & 7 r w 102-a 194-2070 102-b 194-2075 102-2 194-2060 4 & 5 rw 103-a 194-2080 103-b 194-2081 101-2 194-2040 5 rw sh-102-b 194-2085 102-2 194-2060 holders and clamps straight holders s traight holders for multi-spot welding are available in two sizes, to carry tips having four different diameters. series 101 holders are for 4 & 5rw tips, and series 102 holders are for 6 & 7rw tips. they may be ordered with one or two sets of coolant ports. mating electrical contact surfaces of both the barrels and the clamp are silver plated. item numbers for replacement barrels and clamp parts are called out on the drawings. to determine distance adapter sticks out from holder, deduct 1/2fr om length of adapter selected. water tubes 1/2longer than adapter will install approx- imately flush with adapter face. t o determine distance adapter sticks out from holder deduct 3/4from length of adapter selected. water tubes 3/4longer than adapter will install appro x- imately flush with adapter face. clamp and barrel are separate parts adapters, water connectors and water tubes (see page 15 & 16) are sold separately. 1 01 series holders (for 4 & 5 rw tips) 102 series holders (for 6 & 7 rw tips) for water tubes see page 16 for water tubes s ee page 16 194-2080 barrel only for 7/8 - 14 nf adapter 194-2081 barrel only dual w/con. @ 20 offset for 7/8 - 14 nf adapter 194-2085 (1-3/8 diameter barrel) only for 1-12 nf adapter 17 holder clamp 101-2: part no. 194-2040 holder barrel: single-por ted, 101-a: part no. 194-2020 double-ported, 101-b: p a rt no. 194-2025 holder barrel: single-ported, 102-a: part no. 194-2070 double-por ted, 102-b: part no. 194-2075 holder clamp 102-2: p ar t no. 194-2060 1/4 npt hose connector, 8241: p a rt no. 195-8241 adapter (1/2 npt) adapter (3/4 npt) 1/4 npt hose connector, 8241: part no. 195-8241 tuffaloy multi-spot barrel and clamp threaded adapters for barrels can be found on page 16.
tip socket rw 5 /8 4 8 e-05084 320-0100 5/8 4 12 e-05124 320-0120 3/4 4 8 e-06084 320-0140 3/4 5 8 e-06085 320-0150 3/4 4 12 e-06124 320-0160 3/4 5 12 e-06125 320-0170* 7/8 4 8 e-07084 320-0180 7/8 5 8 e-07085 320-0190 7/8 4 12 e-07124 320-0200 7/8 5 12 e-07125 320-0210 1 4 8 e-08084 320-0220 she-08084 321-0220 1 5 8 e-08085 320-0230 she-08085 321-0230 1 6 8 e-08086 320-0240* she-08086 321-0240* 1 4 12 e-08124 320-0250 she-08124 321-0250 1 5 12 e-08125 320-0260 she-08125 321-0260 1 6 12 e-08126 320-0270* she-08126 321-0270* 1-1/4 4 8 e-10084 320-0280 she-10084 321-0280 1-1/4 5 8 e-10085 320-0290 she-10085 321-0290 1-1/4 6 8 e-10086 320-0300* she-10086 321-0300* 1-1/4 7 8 e-10087 320-0310 she-10087 321-0310 1-1/4 4 12 e-10124 320-0320 she-10124 321-0320 1-1/4 5 12 e-10125 320-0330 she-10125 321-0330 1-1/4 6 12 e-10126 320-0340* she-10126 321-0340* 1-1/4 7 12 e-10127 320-0350 she-10127 321-0350 1-1/2 4 8 e-12084 320-0360* she-12084 321-0360 1-1/2 5 8 e-12085 320-0370 she-12085 321-0370 1-1/2 5 8 e-12085-a 320-0375* she-12085-a 321-0375* 1-1/2 6 8 e-12086 320-0380 she-12086 321-0380 1-1/2 6 8 e-12086-a 320-0385 she-12086-a 321-0385 1-1/2 7 8 e-12087 320-0390 she-12087 321-0390 1-1/2 4 12 e-12124 320-0410 she-12124 321-0410 1-1/2 4 12 e-12124-a 320-0415* she-12124-a 321-0415* 1-1/2 5 12 e-12125 320-0420 she-12125 321-0420 1-1/2 5 12 e-12125-a 320-0425* she-12125-a 321-0425* 1-1/2 6 12 e-12126 320-0440* she-12126 321-0440* 1-1/2 7 12 e-12127 320-0450 she-12127 321-0450 tuffaloy straight welding tip holders standard goldcrown cross-section of holders with barrels 1 inch or more in diameter. cross-section of holders with barrels 7/8 inch or less in diameter. goldcrown ? and standard ejector holders with self-adjusting water tubes tuffaloy straight tip-ejecting holders deliver dependable, first class performance. they are designed with maximum simplicity to require minimum maintenance. all tuffaloy straight holders now feature exclusive spring-loaded self-adjusting water tubes to ensure the proper flow of coolant through resistance welding electrodes. the larger ejector holders incorporate bigger fittings for higher coolant flow rates. goldcrown premium holders are made of extra-strength class 2 allo y and are ground and polished to yield greatest conductivity. suffix a in holder description denotes a threaded tip adapter is supplied *item not normally stocked barrel barrel descrip- part descrip- part dia. length tion no. tion no. barrel length ejector tube ejector button o-ring seals self-adjusting water tube 18 part descrip- taper thd no. tion size 195-8550 8550 4rw 5/8-14 npt 195-8551 8551 5r w 5/8-14 npt 190-3615 ad-346-1.5 6rw 3/4-14 npt adapter size for threaded barrels these adapters are supplied with the holder
tip socket rw 5/8 4 8 n-05084 325-0100 5/8 4 12 n-05124 325-0120* 3/4 4 8 n-06084 325-0140 3/4 5 8 n-06085 325-0150* 3/4 4 12 n-06124 325-0160* 3/4 5 12 n-06125 325-0170* 7/8 4 8 n-07084 325-0180 7/8 5 8 n-07085 325-0190* 7/8 4 12 n-07124 325-0200 7/8 5 12 n-07125 325-0210* 1 4 8 n-08084 325-0220 shn-08084 326-0220 1 4 8 n-08084-a 325-0225 shn-08084-a 326-0225 1 5 8 n-08085 325-0230 shn-08085 326-0230 1 5 8 n-08085-a 325-0235* shn-08085-a 326-0235* 1 6 8 n-08086 325-0240* shn-08086 326-0240* 1 4 12 n-08124 325-0250 shn-08124 326-0250 1 4 12 n-08124-a 325-0255 shn-08124-a 326-0255 1 5 12 n-08125 325-0260 shn-08125 326-0260 1 5 12 n-08125-a 325-0265 shn-08125-a 326-0265 1 6 12 n-08126 325-0270* shn-08126 326-0270* 1-1/4 4 8 n-10084 325-0280* shn-10084 326-0280* 1-1/4 4 8 n-10084-a 325-0285 shn-10084-a 326-0285 1-1/4 5 8 n-10085 325-0290 shn-10085 326-0290 1-1/4 5 8 n-10085-a 325-0295 shn-10085-a 326-0295 1-1/4 6 8 n-10086 325-0300* shn-10086 326-0300* 1-1/4 7 8 n-10087 325-0310* shn-10087 326-0310* 1-1/4 4 12 n-10124 325-0320 shn-10124 326-0320 1-1/4 4 12 n-10124-a 325-0325* shn-10124-a 326-0325* 1-1/4 5 12 n-10125 325-0330 shn-10125 326-0330 1-1/4 5 12 n-10125-a 325-0335 shn-10125-a 326-0335 1-1/4 6 12 n-10126 325-0340* shn-10126 326-0340* 1-1/4 7 12 n-10127 325-0350* shn-10127 326-0350* 1-1/2 4 8 n-12084 325-0360* shn-12084 326-0360* 1-1/2 4 8 n-12084-a 325-0365* shn-12084-a 326-0365* 1-1/2 5 8 n-12085 325-0370 shn-12085 326-0370 1-1/2 5 8 n-12085-a 325-0375 shn-12085-a 326-0375 1-1/2 6 8 n-12086 325-0380* shn-12086 326-0380* 1-1/2 7 8 n-12087 325-0390 shn-12087 326-0390 1-1/2 4 12 n-12124 325-0410* shn-12124 326-0410* 1-1/2 5 12 n-12125 325-0420 shn-12125 326-0420 1-1/2 5 12 n-12125-a 325-0425* shn-12125-a 326-0425* 1-1/2 6 12 n-12126 325-0440* shn-12126 326-0440* 1-1/2 7 12 n-12127 325-0450* shn-12127 326-0450* standard goldspot cross-section view of holders with barrels 1 inch or more in diameter. goldspot ? and standard non-ejector holders with self-adjusting water tubes tuffaloy straight non-ejector holders are now equipped with the same springloaded self-adjusting water tubes as the goldcrown ejector unit, so electrode cooling is facilitated and improved. they are low in initial cost and inexpensive to maintain. simple design and few parts contribute to low maintenance cost and excellent performance. holders are heavy- duty and built to withstand very high welding rates. goldspot premium holders have barrels of class 2 allo y, ground and polished for best conductivity. examples of standard holders in use are sho wn on page 22. suffix ain holder description denotes a threaded tip adapter is supplied *item not normally stocked barrel barrel descrip- part descrip- part dia. length tion no. tion no. 19 tuffaloy tip holders part descrip- taper thd no. tion size 195-8550 8550 4rw 5/8-14 npt 195-8551 8551 5rw 5/8-14 npt 190-3615 ad-346-1.5 6rw 3/4-14 npt adapter size for threaded barrels these adapters are supplied with the holder
20 tuffaloy nickel plated ejector holders with self-adjusting water tubes tuffaloy nickel plated ejector holders feature extra strength class 2 tuff 77 alloy and are ground, polished and nickel plated for superior conductivity. these holders also feature exclusive spring-loaded self-adjusting water tubes to ensure proper water flow any electrode. b arrel tip barrel descrip- holder diameter socket rw l ength tion assy. 1 4 8 nhe-08084 319-0213 1 -1/4 4 8 nhe-10084 319-0214 1 5 8 neh-08085 319-0216 1 -1/4 5 8 neh-10085 319-0217 1 4 12 neh-08124 319-0233 1 -1/4 4 12 neh-10124 319-0234 1 5 12 neh-08125 319-0236 1-1/4 5 12 neh-10125 319-0237 descrip- holder 1 head 2 3 tube 4 water 5 hose 6 barrel 7 head 8 all tion assy. assy. barrel assy. tube conn. o-ring o-ring thread nhe-08084 319-0213 195-0101 001-213b 195-0210 195-0017 195-8240 195-8251 037-0096 195-0031 nhe-10084 319-0214 195-0101 001-214b 195-0210 195-0017 195-8240 195-8251 037-0096 195-0031 neh-08085 319-0216 195-0100 001-216b 195-0208 195-0015 195-8240 037-0099 037-0096 195-0030 neh-10085 319-0217 195-0100 001-217b 195-0208 195-0015 195-8240 037-0099 037-0096 195-0030 neh-08124 319-0233 195-0101 001-233b 195-0211 195-0017 195-8240 195-8251 037-0096 195-0031 neh-10124 319-0234 195-0101 001-234b 195-0211 195-0017 195-8240 195-8251 037-0096 195-0031 neh-08125 319-0236 195-0100 001-236b 195-0212 195-0015 195-8240 037-0099 037-0096 195-0030 neh-10125 319-0237 195-0100 001-237b 195-0212 195-0015 195-8240 037-0099 037-0096 195-0030 tuffaloy nickel plated ejector holders
body tip descrip- part dia. socket tion no. 3/4 4rw n-06034 330-0140 7/8 4rw n-07034 330-0180 7/8 5rw n-07035 330-0190 1 4rw n-08034 330-0220 1 5rw n-08035 330-0230 1-1/4 4rw n-10034 330-0280 1-1/4 5rw n-10035 330-0290 1-1/2 4rw n-12034 330-0360* 1-1/2 5rw n-12035 330-0370* closed-coupled holders adjustable water tube use for use where welding space is limited. standard body length is 3 inches. other lengths are made on request; minimum length 2 inches. it is v er y important that resistance welding electrodes be kept as cool as possible; excessive heat softens them, allowing the nose to mushroom and weld quality to drop. adjustable water tubes ar e used to deflect incoming coolant water to the full extent of the water hole in the electrode. befor e installing a tip , check that there is an adjustable water tube in place and that it is pulled out far enough so that it will contact the end of the water hole in the tip. the drawing shows a typical straight holder, but the principle is the same for all types of holders. adjustable water tube correctly positioned in tip. cold water will strike the hottest part of the tip first. *item not normally stocked barrel length 3 6 5/16 o.d. tube 1/4 o.d. adjustable water tube shank length 4-1/8 rw taper socket 60 21 tuffaloy tip holders
barrel length hole dia. (tee connector) 2-1/4 shank dia. 90 30 shank length 4 barrel dia. holders tee connectors barrel barrel descrip- part hole shank descrip- part dia. length tion. no. d ia. dia. tion no. 1 8 n-08085-a 325-0235 1 1 t-1-1 192-1100 1-1/4 8 n-10085-a 325-0295 1-1/4 1 t-1 192-1000 1-1/4 8 n-10085-a 325-0295 1-1/4 1 t-1 192-1000 1-1/4 8 n-10085-a 325-0295 1-1/4 1-1/4 t-125 192-1250 1-1/4 8 n-10085-a 325-0295 1-1/4 1-1/4 t-125 192-1250 1-1/4 8 n-10085-a 325-0295 1-1/4 1-1/4 t-125 192-1250 1-1/2 8 n-12085-a 325-0375 1-1/2 1-1/2 t-15 192-1500 1-1/2 8 n-12085-a 325-0375 1-1/2 1-1/2 t-15 192-1500 1-1/2 8 n-12085-a 325-0375 1-1/2 1-1/2 t-15 192-1500 abc arm hole arm diameter diameter* length 12 sh-7320-1 630-7321 2 1 16 sh-7320-2 630-7322 20 sh-7320-3 630-7323 12 sh-7320-4 630-7324 2-1/2 1-1/4 16 sh-7320-5 630-7325 20 sh-7320-6 630-7326 12 sh-7320-7 630-7327 3 1-1/2 16 sh-7320-8 630-7328 20 sh-7320-9 630-7329 *these diameters will be supplied unless otherwise specified. universal holder assemblies holders, tee connectors, and adapters may be assembled as shown, line by line in the table, to make up holder assemblies that will do spot welding in many otherwise inaccessible places. goldcrown (ejector-type) holders may be used in place of the non-ejector holders listed. the tee connector is class 3 rwma alloy. class 2 s pot welding machine arms made by tuffaloy reduce set up time and give longer life. electr ode holder shanks can be attached to these arms from the front, by bolting the cap over them. this means no extra clearance is required between the arms to allow running a shank up (or down) into a hole in the arm. it makes the insertion of tuffaloy multiple- welding holders much easier. one of the most common failures of welder arms is the destruction of the bolt hole threads, due to the relatively soft copper involved. tuffaloy arms have a transverse steel bar insert in which the bolt hole thr eads are cut. this provides greatly increased thread life. standard arm configurations are shown in the table. special arms are also available. descrip- tion part no. ad-584-30, for 4rw tip part no. 190-8430 ad-585-30, for 5rw tip part no. 190-8530 ad-584-90, for 4r w t ip part no. 190-8490 ad-585-90, for 5r w t ip part no. 190-8590 ad-585-90e, for 5rw tip part no. 190-9590 adapters to choose from tip angle descrip- part socket d egrees t ion no. 4rw 90 ad-584-90 190-8490 4r w 30 ad-584-30 190-8430 5rw 90 ad-585-90 190-8590 5rw 30 ad-585-30 190-8530 6rw 90 ad-586-90 190-8690 22 tuffaloy offset holders tuffaloy welder arms
3/4 7/8 1 1-1/4 1-1/2 shank dia. shank dia. shank dia. shank dia. shank dia. descrip- part descrip- part descrip- part descrip- part descrip- part tion no. tion no. tion no. tion no. tion no. 4rw 30 on-754-230 335-1300 on-874-230 335-1400* on-14-230 335-1000 on-1254-230 335-1100 on-154-230 335-1200* 4r w 90 on-754-290 335-1310* on-874-290 335-1410* on-14-290 335-1010 on-1254-290 335-1110 on-154-290 335-1210* 5rw 30 on-755-230 335-1350* on-875-230 335-1450* on-15-230 335-1050 on-1255-230 335-1150 on-155-230 335-1250* 5rw 90 on-755-290 335-1360* on-875-290 335-1460* on-15-290 335-1060 on-1255-290 335-1160 on-155-290 335-1260 4rw 30 on-754-430 335-1320* on-874-430 335-1420* on-14-430 335-1020 on-1254-430 335-1120 on-154-430 335-1220* 4rw 90 on-754-490 335-1330* on-874-490 335-1430* on-14-490 335-1030 on-1254-490 335-1130 on-154-490 335-1230* 5rw 30 on-755-430 335-1370* on-875-430 335-1470* on-15-430 335-1070 on-1255-430 335-1170 on-155-430 335-1270 5rw 90 on-755-490 335-1380* on-875-490 335-1480* on-15-490 335-1080 on-1255-490 335-1180 on-155-490 335-1280 two-inch offset holders f igure 1: an offset holder over a lo w-profile paddle-type holder that works in confined spaces. figur e 2: an offset holder with bent tip is used to weld close to the corner of a box section. figur e 3: a universal holder (economical because it adjusts to many jobs) over a close- coupled holder. figur e 4: a platen set-up using platen-mounted standard tips under an equa-press dual holder. standard offset holders t uffaloy cast class 3 alloy offset holders combine long life with good conductivity. threaded tip adapters are easily replaced when tip socket is worn beyond use, or when you wish to change to a different taper size. tuffaloy offset holders are made in 2- and 4-inch offsets, and in four shank sizes, with 90 and 30* heads. they are supplied with adapters for no. 4 or no. 5 rw taper tips. tip ejector mechanisms are available on all 90* head holders and the 30 head 4-in. offset holders. when ordering this feature change order number pr efix from n to e?example: oe-874-290. *may not be in stock offset 2 or 4 2 (max.) 30 shank length 3-1/2 socket angle adapter tip socket four-inch offset holders using standard holders head height 2 1/4on ejector-type model adapters supplied: 4rw: ad-584 5rw: ad-585 23 tuffaloy standard offset holders
3-1/2 3-1/2 4 min. 5 max. shank descrip- part dia. tion no. 1 sh-7223 345-7223 1-1/4 sh-7224 345-7224 1-1/2 sh-7225 345-7225 variable-offset holders type nose length descrip- part of t ip tion no. pointed 1 se-4408-1 170-4408 of fset 1 se-4409-1 170-4409 15 dome 1 se-4410-1 170-4410 30 dome 1 se-4411-1 170-4411 pointed 2 se-4408-2 170-4418 offset 2 se-4409-2 170-4419 15 dome 2 se-4410-2 170-4420 30 dome 2 se-4411-2 170-4421 straight-shank tips tuffcap nose cap length angle type male 3/4 90 se-4412 170-4422 male 3/4 15 se-4413 170-4423 female 1 90 se-4414 170-4424 female 1 15 se-4415 170-4425 straight-shank tuffcap shanks v ariable offset holder and straight shank tips these offset holders provide a range of offset dimensions rather than one fixed amount, as with other one-piece offset holders. the top has a long shank and can be moved in or out to vary the offset anywhere between four and five inches. the holders, all of class 3 alloy, are made in three barrel diameters: 1, 1-1/4, and 1-1/2 inches. the tips are positional because they have no taper: they have straight shanks, and are held in any selected position b y a locking-w edge device in the holder. tips ar e made in one and two-piece designs. the one-piece tips are offered with the nose designs shown. the two-piece tips ar e made up b y combining the shanks shown her e with t uffcap caps (normally used with no . 5 rw siz e tuffcap shanks). either male or female tips can be used, with any #5 nose design offered on pages 6 & 7. all integral tips and shanks shown here are of class 2 alloy. descrip- tion part no. 24 tuffaloy variable-offset holders
offset se-3248 part no. 170-3248 flat faced se-3249 part no. 170-3249 tuffaloy paddle-type holders and socket-type tips this holder is for welding in very restricted areas. it provides a very l ow head height and a four-inch offset. it is made in shank diameters of 3/4, 7/8, 1, and 1-1/4 inches. an adapter bushing is used to add a 1-1/2-in. dia. model to the line. each holder comes complete with a socket-type tip (se-3101) and holding screw. the tip may be inserted in either side of the paddle. holders are of class 2 alloy. tips are a vailable in class 1, class 2, class 3 alloy, or z alloy. the four socket-type tips shown here can be used in special welding fixtures and dies as well as in the paddle-type holders. flat faced class 1 se-3099-1 part no. 170-3099-1 class 2 se-3099 part no. 170-3099 class 3 se-3111 part no. 170-3111 zirc se-3099-z part no. 170-3099-z truncated cone class 1 se-3101-1 part no. 170-3101-1 class 2 se-3101 part no. 170-3101 class 3 se-3113 part no. 170-3113 zirc se-3101-z part no. 170-3101-z offset class 1 se-3102-1 part no. 170-3102-1 class 2 se-3102 part no. 170-3102 class 3 se-3123 part no. 170-3123 zirc se-3102-z part no. 170-3102-z radius faced class 1 se-3110-1 part no. 170-3110-1 class 2 se-3110 part no. 170-3110 class 3 se-3133 part no. 170-3133 zirc se-3110-z part no. 170-3110-z tuffaloy heavy-duty paddle-type holders and tips tuf faloy heavy-duty paddle-type holders are made of the stronger class 3 alloy, for greater rigidity and minimum deflection, even under loads of 1000 pounds and more. class 3 alloy provides 154% more tensile strength. head height is a lo w 3/4-in. and the shank length is a usable 4 inches. thr ee lo w-pr ofile electrodes of class 2 alloy are offered for use in this heavy-duty holder. if applications permit greater head height, any standard no. 4 rw tip may be used. offset 4 11/16 shank length 3 offset 4 3/4 shank length 4 truncated cone se-3247 part no. 170-3247 shank descrip- part dia. tion no. 1 sh-7194 345-7194 1-1/4 sh-7195 345-7195 1-1/2 sh-7196 345-7196 shank descrip- part dia. tion no. 3/4 p-750-490 345-0750 7/8 p-870-490 345-0870 1 p-100-490 345-1000 1 -1/4 p-120-490 345-1200 1-1/2 p-150-490 345-1500 25 tuffaloy paddle-type holders
size barrel descrip- part dia. tion no. 1 1 4511 350-4511 1 1-1/4 4512 350-4512 1 1-1/2 4513 350-4513 2 1-1/4 4521 350-4521 2 1-1/2 4522 350-4522 size 1 pmc-2503 part no. 180-2203 part no. 180-2203-10w size 2 pmc-2104 part no. 180-1040 part no. 180-2104-10w size 1 pme-2503 part no. 180-2303 size 2 description part no. 1/4 pme-21041 180-1041 5/16 pme-21042 180-1042 3/8 pme-21043 180-1043 7/16 pme-21044 180-1044 1/2 pme-21045 180-1045 size 1 pmb-2503 part no. 180-2103 high pressure tips s pot and projection welding operations may utilize pressures over 2000 lbs. tuffaloy high-pressure tips have flat bottoms which eliminates tip jamming in tapered holders. assembled tip and holder heights are always the same, as contrasted to tapered tips which can be forced into the sockets varying distances. tuffaloy high pressure tips can be used in the two holder styles shown: pm holders for mounting on the platens of press-type welders, and straight holders for spot welder arm mounting. the tips are held to the holders by a threaded coupling. copper tungsten faced tips are available for high pressure wear and projection welding. straight holders class 2 alloy straight holders are made for carrying tuffaloy high pressure tips in rocker arm welders or press-type welder horn extensions. they ar e made in two basic sizes, to accommodate the size 1 and 2 tips. they are of class 2 alloy and hold the tips in the same manner as do the p m holders. truncated cone dome nosed flat faced 1-3/4 5-5/16 3-1/2 26 tuffaloy high pressure welding
pm holders tuffaloy pm holders are mounted directly to press- type welder platens, or ar e used as components of special weld fixturing. platen mounting: p m holders bolt easily to the platen t-slots at any desired location, in a minimum of time (no intermediar y device is r equir ed). big half- inch mounting bolts may be used to assure good conductivity . they ar e the first such standard, stocked holders to be made av ailable. they come in two siz es, to match standard t-slot spacing, and to hold the 2 siz es of tips sho wn. the small siz e 1 p m holder is for use on rwma size 1 press-type welders (3-1/2 in. spacing) and the large size, 2 pm holder is for size 2 and 3 welders (5- and 6-in. spacing). the electrodes used do not require any particular radial positioning to obtain proper coolant flow. these are compact holders that may be used one-to-one or in multiples in close proximity to one another. fixture building: pm holders make special fixture building easy too . they can be bolted to a fixture or backup base as easily as to a platen. they are compact and have self-contained coolant systems that eliminate making a coolant manifold out of the fixture. hose connections: you may specify where you want the hose connectors in the hexagonal base. select any two of the six possible locations and specify by using the symbols shown on the diagram (connector locations: a-b, or a-d, etc.). position a-c is standard. (a-f and c-d are not possible.) size 1 pm holder (9/16-in. mounting bolts) 4510 holder, part no. 350-4510 size 2 pm holder (3/4-in. mounting bolts) 4520 holder, part no. 350-4520 7 3/4 1-5/8 2-3/8 1 body is 2wide body is 1-1/2wide 27 tuffaloy high pressure welding
size 1 (small) size 2 (large) descrip- par t descrip- part tion no. tion no. 4 4560 350-4560 4570 350-4570 5 4561 350-4561 4571 350-4571 6 4562 350-4562 4572 350-4572* 7 4563 350-4563 4573 350-4573 standard tip pm holders for 1dia. electrodes for 1-1/2dia. electrodes description part no. description part no. 3-1/2 1pm 4515 350-4515 5 & 6 2pm 4525 350-4525 4526 350-4526 thread size size 1 size 2 5/8-11 350-4580 350-4590 3/4-10 350-4581 350-4591 for threaded electrodes pm holders t uffaloy pm holders may be mounted directly to press- type welder platens, or they can be used as components of special weld fixturing. they come in two sizes, which match standard t-slot spacings (either of which can be furnished to hold any of the four standard tips: 4, 5, 6 or 7 rw). the smaller holder is for use on rwma size 1 welders, which have the 3-1/2spacing. the larger one is for the size 2 and 3 welders, which have the 5- and 6-inch spacing. big, half-inch mounting bolts may be used to assure good conductivity. the holders may be used one-to- one or in multiples closely bunched. pm holders make special fixture building easy. they can be bolted to a fixture or back-up base as easily as to a platen. they are compact and have self-contained coolant systems. *item not normally stocked rw tip socket pm holders holder t -slot spacing size size 2 pm holder size 1 pm holder 2-3/8 7/8 7 1-5/8 size 2 pm holder (3/4-in. mounting bolts) 1/2" 4-1/4" 1-3/4" thread size 1-1/2" hex. (pipe thread on request) 7/8-14 & 1-12 onl y this style only body is 2wide body is 1-1/2wide thr ead size size 1 size 2 7/8-14 350-4582 350-4592 1-12 350-4583 350-4593 for threaded adapters see adapters page 16 28 tuffaloy platen-mounted holders
e f g with 10w face for nut pin electrode electrode refractory - size length length diameter item number .164 3/16 411 175-4111 175-4111-10w .190 3/16 412 175-4121 175-4121-10w .216 1/4 413 175-4131 175-4131-10w 1/4 5/16 2-1/4 1 414 175-4141 175-4141-10w 5/16 & 8mm 5/16 415 175-4151 175-4151-10w 3/8 3/8 416 175-4161 175-4161-10w 6mm 1/4 606 175-6061 175-6061-10w 7mm 5/16 607 175-6071 175-6071-10w 9mm 3/8 609 175-6091 175-6091-10w 10mm 3/8 610 175-6101 175-6101-10w 3/8 3/8 456 175-4561 175-4561-10w 7/16 3/8 457 175-4571 175-4571-10w 1/2 7/16 458 175-4581 175-4581-10w 9/16 7/16 2-3/4 1-1/2 459 175-4591 175-4591-10w 5/8 1/2 460 175-4601 175-4601-10w 11/16 1/2 461 175-4611 175-4611-10w 3/4 5/8 462 175-4621 175-4621-10w 10mm 3/8 610-2 175-6102 175-6102-10w 12mm 7/16 612-2 175-6122 175-6122-10w self-pil oted-nut electrodes w ith 10w face a b c refractory - item number .150 400 175-4001 175-4001-10w .164 401 175-4011 175-4011-10w .190 402 175-4021 175-4021-10w .216 403 175-4031 175-4031-10w 1/4 2-1/4 1 404 175-4041 175-4041-10w 5/16 & 8mm 405 175-4051 175-4051-10w 3/8 406 175-4061 175-4061-10w 6mm 506 175-5061 175-5061-10w 7mm 507 175-5071 175-5071-10w 9mm 509 175-5091 175-5091-10w 10mm 510 175-5101 175-5101-10w 3/8 4 36 175-4361 175-4361-10w 7/16 437 175-4371 175-4371-10w 1/2 438 175-4381 175-4381-10w 9/16 2-3/4 1-1/2 439 175-4391 175-4391-10w 5/8 440 175-4401 175-4401-10w 11/16 4 41 175-4411 175-4411-10w 3/4 442 175-4421 175-4421-10w 10mm 510-2 175-5102 175-5102-10w 12mm 512-2 175-5122 175-5122-10w stud electrodes electrodes stud electrodes tuffaloy stud electrode tips ar e for projection-welding screws, bolts or pins, whether they pass through the sheet or are to be attached directly to its face. n ut e lectrodes tuffaloy projection weld nut electr odes ar e designed for either self-piloted or non- piloted nuts. the pilots of the non-piloted-nut electrodes are spring-loaded so they can interfere with the contacting of nut and sheet under welding pressure. the various types and sizes of tuffaloy stud-and-nut welding electrodes and holders are described below. for excessive wear applications any of these electrodes may be ordered with refractory metal facings, such as tuffaloy 10w. welding a stud through a hole in sheet metal. w elding a stud directly to face of sheet metal. self-piloted nut aligns itself with the hole in sheet. non-piloted-nut is guided by specially designed electr ode. descrip- tion part no. descrip- tion part no. j k l with 10w face for nut pin electrode electrode refractory - size diameter length diameter item number .164 0.18 421 175-4211 175-4211-10w .190 0.215 422 175-4221 175-4221-10w .216 0.24 423 175-4231 175-4231-10w 1/4 0.275 2-1/4 1 424 175-4241 175-4241-10w 5/16 & 8mm 0.345 425 175-4251 175-4251-10w 3/8 0.405 426 175-4261 175-4261-10w 6mm 0.261 706 175-7061 175-7061-10w 7mm 0.3 707 175-7071 175-7071-10w 9mm 0.385 709 175-7091 175-7091-10w 10mm 0.425 710 175-7101 175-7101-i0w 3/8 0.437 476 175-4761 175-4761-10w 7/16 0.562 477 175-4771 175-4771-10w 1/2 0.625 2-3/4 1-1/2 478 175-4781 175-4781-10w 9/16 0.687 479 175-4791 175-4791-i0w 5/8 0.75 480 175-4801 175-4801-10w 10mm 0.453 710-2 175-7102 175-7102-10w 12mm 0.595 712-2 175-7122 175-7122-10w non-pilo ted-nut electrodes descrip- tion part no. 29 this style holder found at bottom of page 27 this style holder found at top of page 29 tuffaloy nut and stud welding
1-3/4 5-5/8 3-1/2 abc for stud electrode electrode diameter length diameter 0.150 115 175-1151-x 0.164 116 175-1161-x 0.190 3 1-1/4 119 175-1191-x 0.216 122 175-1221-x 1/4 125 175-1252-x 5/16 & 8mm 131 175-1312-x 3/8 138 175-1382-x 7/16 144 175-1442-x 6mm 106 175-1061-x 7mm 107 175-1072-x 9mm 109 175-1092-x 10mm 110 175-1102-x 1/2 150 175-1503-x 9/16 3 1-1/2 156 175-1563-x 5/8 163 175-1633-x 11/16 169 175-1693-x 12mm 112 175-1123-x hjkl for nut pilot electrode electrode diameter diameter length diameter 0.164 0.180 216 175-2162-x 0.190 0.215 219 175-2192-x 0.216 0.240 222 175-2222-x 1/4 0.275 4 1-1/4 225 175-2252-x 5/16 & 8mm 0.345 231 175-2312-x 3/8 0.405 238 175-2382-x 6mm 0.261 206 175-2062-x 7mm 0.300 207 175-2072-x 9mm 0.385 209 175-2092-x 10mm 0.425 210 175-2102-x 7/16 0.562 244 175-2443-x 1/2 0.625 4 1-1/2 250 175-2503-x 9/16 0.687 256 175-2563-x 12mm 0.595 212 175-2123-x ar ctic stud electrodes ar ctic non-p ilo ted-nut electr odes electrode holders u .s. pat. no. 3,504,159 canada pat. no. 858,060 s ev eral standard electrode holders are manufactured by tuffaloy to accommodate all the tuffaloy stud-and nut electrode tips. straight holders - tuffaloy str aight nut-and-stud-electrode holders are of the same high quality as the standard straight holders made for spot welder arm mounting. coolant is brought to the tip and circulated around it. holders are available in three barrel diameters. for 1dia. for 1-1/2dia. e lectrodes electrodes descrip- part descrip- part t ion no. tion no. 1 1-3/4 5-5/8 4530 350-4530 1 -1/4 1-3/4 5-5/8 4531 350-4531 1-1/2 1-3/4 5-5/8 4532 350-4532 1 2 5-3/4 4535 350-4535 1 -1/4 2 5-3/4 4536 350-4536 1 -1/2 2 5-3/4 4537 350-4537 straight holders a b barrel dia. length diameter ar ctic electrodes - the arctic system is a compact stud-and- nut electr ode with internal water cooling. also available with optional air expulsion and platen mounts. p atent p ending descrip- tion part number shank size descrip- tion part number shank size straight holder ar ctic holders 30 tuffaloy nut and stud welding
part a b c d description number oal dia. thread taper tdh-25a 301-0004 1.77 1 18mm #4 tdh-25c 301-0005 1.97 1 18mm #5 tdh-30a 301-0015 1.97 1.125 22mm #5 tdh-35a 301-0020 1.97 1.125 26mm #5 bodies part hole a b c copper-tungsten number dia. pin size thread dia. faced heads 175-8004 .197 4mm 175-8004-10w 175-8005 .236 5mm 175-8005-10w 175-8006 .276 6mm 175-8006-10w 175-8007 .315 7mm m18 1.0 175-8007-10w 175-8008 .354 8mm 175-8008-10w 175-8009 .394 9mm 175-8009-10w 175-8010 .432 10mm 175-8010-10w 175-8011 .472 11mm m22 1.125 175-8011-10w 175-8012 .512 12mm 175-8012-10w 175-8013 .551 13mm 175-8013-10w 175-8014 .588 14mm m26 1.250 175-8014-10w heads metric nut electrodes tuffaloy now stocks the head/pin style welding system components that adds to your selection for stud and nut welding needs. from our standard style to our arctic, that produces higher quality welds and longer life, you can select the product that best meets your needs. heads are made from rwma class 2 material that are an optimal cost consumable. class 3 and 10w are available for longer life. with a concave seat the pin locates in the center of assembly when air is applied to the system. this gives you a repeatable location for automated nut feeders to introduce the nut to the environment. pins have a nonconductive surface on a steel matrix that gives longer life in a repetitive motion environment. with the thr eaded head securing the pin in place it makes it easy to replace the pin to meet your requirements. tuffaloy can design pins for special applications. a pilot part a b c pilot dia. number nut oal base 195-3004 4mm 1.12 .185 195-3005 5mm 1.17 .224 195-3006 6mm 1.23 .264 195-3007 7mm 1.24 12mm .303 195-3008 8mm 1.25 .340 195-3009 9mm 1.19 .380 195-3010 10mm 1.37 .422 195-3011 11mm 1.38 16mm .458 195-3012 12mm 1.40 .500 195-3013 13mm 1.37 .539 195-3014 14mm 1.50 .815 .580 195-3015 15mm 1.52 .815 .620 pins part a b c d description number id oal dia. t aper tnfd 16-m5-16-3 186-0101 5mm .625 tnfd 20-m6-16-3 186-0102 6mm .75 tnfd 20-m8-16-3 186-0103 7.5mm 2.36 .75 5rw tnfd 20-m10-16-3 186-0104 10mm .75 tnfd 20-m12-16-3 186-0105 12mm .75 upper electrode 31 tuffaloy automatic nut feeder system components
1 75-gh-2 series 175-gh-3 series 175-gh-4 series insert i.d. 0.875 1.000 1.125 0.875 1.250 1.500 1.000 1.375 1.500 175-gh-2-188 175-gh-3-188 0.188 175-gh-2-193 175-gh-3-193 0.193 175-gh-2-197 0.197 175-gh-3-200 0.200 175-gh-2-212 0.212 175-gh-2-218 0.218 175-gh-2-239 0.239 175-gh-2-240 0.240 175-gh-2-242 175-gh-3-242 (6mm) 0.242 175-gh-2-245 175-gh-3-245 0.245 175-gh-3-247 0.247 175-gh-2-250 0.250 175-gh-3-251 0.251 175-gh-2-252 0.252 175-gh-3-254 0.254 175-gh-2-258 0.258 175-gh-3-262 0.262 175-gh-2-263 0.263 175-gh-3-264 0.264 175-gh-2-272 175-gh-3-272 0.272 175-gh-2-273 175-gh-3-273 0.273 175-gh-2-275 0.275 175-gh-2-277 0.277 175-gh-2-280 0.280 175-gh-2-282 0.282 175-gh-2-287 0.287 175-gh-2-312 175-gh-3-312 0.312 175-gh-3-317 (8mm) 0.317 175-gh-2-322 175-gh-3-322 0.322 175-gh-2-325 175-gh-4-325 0.325 175-gh-3-326 0.326 175-gh-3-332 0.332 175-gh-3-337 0.337 175-gh-2-342 0.342 175-gh-2-347 175-gh-3-347 0.347 175-gh-3-351 175-gh-4-351 0.351 175-gh-2-352 175-gh-3-352 0.352 175-gh-2-354 0.354 175-gh-2-357 175-gh-3-357 0.357 175-gh-2-359 0.359 gh series nut welding heads 1 75-gh-2 series 175-gh-3 series 175-gh-4 series insert i.d. 0.875 1.000 1.125 0.875 1.250 1.500 1.000 1.375 1.500 175-gh-2-368 0.368 175-gh-2-372 175-gh-3-372 0.372 175-gh-3-392 0.392 175-gh-3-397 (1 0mm) 0.397 175-gh-3-412 0.412 175-gh-3-417 0.417 175-gh-3-423 0.423 175-gh-3-425 0.425 175-gh-3-427 0.427 175-gh-3-430 0.430 175-gh-3-432 0.432 175-gh-3-437 0.437 175-gh-3-445 0.445 175-gh-3-447 0.447 175-gh-3-452 0.452 175-gh-3-465 0.465 175-gh-3-467 0.467 175-gh-3-470 0.470 175-gh-3-472 0.472 175-gh-3-480 (12mm) 0.480 175-gh-3-504 0.504 175-gh-3-507 0.507 175-gh-3-508 0.508 175-gh-4-509 0.509 175-gh-3-512 0.512 175-gh-3-517 0.517 175-gh-3-522 0.522 175-gh-3-538 0.538 175-gh-3-542 0.542 175-gh-3-547 0.547 175-gh-3-548 0.548 175-gh-3-552 0.552 175-gh-3-557 0.557 175-gh-3-587 0.587 175-gh-3-592 0.592 175-gh-3-632 0.632 175-gh-3-656 0.656 175-gh-4-667 0.667 175-gh-4-677 0.677 length tungsten od hex size length hex size insert i.d. copper tungsten o.d. tuffaloy automatic nut feeder system components 32
insulator screw id. length part thread size a b number .218 175-0316-4032-10w 6mm .243 175-0316-40062-10w 0.250 .256 175-0316-4042-10w 0.312, 8mm .319 1 175-0316-4052-10w 0.375 .381 175-0316-4062-10w 10mm .400 175-0316-40102-10w .218 175-0316-4031-10w 6mm .243 175-0316-4006-10w 0.250 .256 175-0316-4041-10w 0.312, 8mm .319 2 175-0316-4051-10w 0.375 .381 175-0316-4061-10w 10mm .400 175-0316-4010-10w 0.437 .444 175-1313-4372-10w 12mm .479 175-1313-40122-10w 0.500 .506 175-1313-4382-10w .569 1 175-1313-4392-10w 0.625 .652 175-1313-4402-10w .694 175-1313-4412-10w .777 175-1313-4422-10w 0.437 .444 175-1313-4371-10w 12mm .479 175-1313-4012-10w 0.500 .506 175-1313-4381-10w .569 2 175-1313-4391-10w 0.625 .652 175-1313-4401-10w .694 175-1313-4411-10w .777 175-1313-4421-10w backup electrodes for uppers these series of stud electrodes are made from rwma class 2 material with tuffaloys 10w (copper tungsten) on the w eld face and wrench flats for easy removal from holders. the insulator is made to withstand the constant friction that is applied as the stud is inserted and removed. 186-0311-10w 186-0316-10w 186-0313-10w 186-1313-10w 33 tuffaloy 5 rw stud electrodes
tip style shank descrip- spacing socket taper tion* range taper (inches) 4rw tt-1408 1-1/4 to 2 4rw 5r w 4ct 5ct light 4rw tt-1416 2 to 4 4rw 5r w 4ct 5ct duty 5rw tt-1508 1-1/2 to 2 4rw 5r w 4ct 5ct 5rw tt-1516 2 to 4 4rw 5rw 4ct 5ct 5rw tt-15516 2 to 4 4rw 5rw 4ct 5ct 5rw tt-15524 4 to 6 4rw 5rw 4ct 5ct heavy 6rw tt-15616 2 to 4 4rw 5rw 4ct 5ct duty 6rw tt-15624 4 to 6 4rw 5rw 4ct 5ct 7rw tt-15716 2 to 4 4rw 5rw 4ct 5ct 7rw tt-15724 4 to 6 4rw 5rw 4ct 5ct quickest way to cut welding costs increased productivity without capital investment or increased labor costs just has to spell profit. hundreds of resistance welding users are profiting from the tuffaloy methods of multiple welding, to produce almost any assembly requiring closely spaced welds. the key is to think multiple! whenever the welding machine goes through a cycle, have it do more than one weld at a time. it s easy and practical with one of the tuffaloy multiple welding devices: the teeter-tip dual tip adapter, the equatip dual tip holder, the equa-press dual tip holder, or the tri-spacer. theyre ready to go to work, cutting costs and increasing production efficiency for you. study the multiple welding holders and adapters in this section. learn their capabilities, think multiple, and youll pr obably see many ways in which tuffaloy multiple welding can improve your operation. remember that tuffaloy is prepared to provide any special fixturing you need. show our engineers what you require, and theyll design a set-up to do it. *when ordering, also state exact tip spacing and tip socket size, example: tt - 1508 - 1-1/2 - 5ct. (5ct means 5/8diameter cap, 4ct means 1/2diameter cap.) teeter-tip dual tip adapters u.s. pat. 3,356,821 you can spot or projection weld in half the time by doubling the number of welds per machine str oke. use teeter-tip dual tip adapters, which come with water- coolant fittings to beat high heat build-up . these, adapters transmit total pressures of 1000 lbs., and deliver equal current and pressure to each tip. they compensate for normal electrode wear, imperfect tip dressing, and work variations up to .060 light-duty adapters have no. 4 or 5 rw shanks, tip spacing to 4 inches, tip sockets for 1/2or 5/8?iameter male tuffcap caps, or 4 rw tips (5/8cap sockets are standard). heavy-duty adapters have shanks from 5 to 7 rw size, tip spacing to 6 inches, tip sockets for 1/2or 5/8?iameter male tuffcap caps, or 4 or 5 rw tips (4 rw sockets are standard). these adapters have a deeper, stronger body. two low-height 5/8dia. cap--ype tips are shown below. they are recommended for use in these adapters. other standard caps, both 5/8& 1/2?ia., are tabled on the next page. you must specify the siz e tip sockets you want, or the standar d socket will be supplied. trunca ted cone se-6332 (part no. 186-0522) flat faced se-6296 (par t no. 186-0523) light duty heavy duty 34 tuffaloy multiple welding
nose alloy descrip- part style class tion no. pointed 1 ta-14 111-0014 2 ta-24 112-0024 dome 1 tb-14 113-0014 2 tb-24 114-0024 flat 1 tc-14 115-0014 2 tc-24 116-0024 offset 1 td-14 117-0014 2 td-24 118-0024 1/2dia. tuffcap caps (4 ct) for 5/8dia. for no. 4 tuffcap caps rw tips tip spacing & descrip- part descrip- part mounting style tion no. tion no. one-inch sp acing: 1-in. shank 4050 350-4050 4055 350-4055 1-1/4-in. shank 4051 350-4051 4056 350-4056 1-1/2-in. shank 4052 350-4052 4057 350-4057 5r w adapter 4053 350-4053 4058 350-4058 cylinder adapter* 4054 350-4054 4059 350-4059 1-1/2-inch spacing: 1-in. shank 4150 350-4150 4155 350-4155 1-1/4-in. shank 4151 350-4151 4156 350-4156 1-1/2-in. shank 4152 350-4152 4157 350-4157 5rw adapter 4153 350-4153 4158 350-4158 cylinder adapter* 4154 350-4154 4159 350-4159 equatip holders equatip dual tip holders u .s. pat. no. 3,558,847 the equatip dual tip holder is a smaller version of the equa-press holder (on next page). it is more compact, and is more economical for those applications where it will work equally well. an even smaller device, the equatip adapter (not water-cooled) is shown in box below. using the equatip holder, both tips contact the work squarely, because tip axes remain parallel to direction of force (unlike the teeter-tip adapters). an internal roller equalizes current and pressure between the two electrodes, and will compensate for work height variations up to 1/16 the holders are ordered with either 1or 1-1/2 spacing between barrels, and with tip sockets to accept either male tuffcap caps (5/8dia.) or straight no. 4 rw electrodes. (bent tips are not recommended.) the distance between welds can be varied by rotating offset-nose tips in the barr els. equatip holders can be supplied with straight shanks for arm mounting, a tapered adapter shank for holder mounting, or a cylinder adapter shank to be clamped to a cylinder r od. equatip holders can be used with forces up to 1000 lbs. cylinder-mounting adapter shank, part no. 195-7063; clamp, part no. 194-2040, not included 5 rw taper adapter shank, part no. 195-5680 for light-duty welding equatip adapter the equatip dual tip adapter works like the equatip holder, but it is not water-cooled and is meant for less demanding jobs. it costs less, and is a little smaller, barrels being 5/8apart. its straight tips are tuffcap caps, 1/2in diameter. those caps are fully dimensioned on page 6. those caps are fully dimensioned on page 6. *without clamp nose alloy descrip- part style class tion no. pointed 1 ta-15 111-0015 2 ta-25 112-0025 dome 1 tb-15 113-0015 2 tb-25 114-0025 flat 1 tc-15 115-0015 2 tc-25 116-0025 offset 1 td-15 117-0015 2 td-25 118-0025 5/8dia. tuffcap caps (5 ct) 4045, par t no. 350-4045-5rw 4046, part no. 350-4046-4rw 2-7/8 7/16 1/2 1 or 1-1/2 1/2 4 body is 1 thick 35 tuffaloy multiple welding
standard design short design mounting style descrip- part descrip- part tion no. tion no. 1-in. shank 4010 350-4010 4015 350-4015 1-1 /4-in. shank 4011 350-4011 4016 350-4016 1-1 /2-1n. shank 4012 350-4012 4017 350-4017 platen 4013 350-4013 4018 350-4018 the equa-press holder makes two identical welds at once. when it contacts the workpiece, the forging pressure is automatically equalized between the two electrodes, r egar dless of variations in work thickness, or electrode wear (up to 3/16. the two tip-holding barrels are sliding pistons, whose movements ar e contr olled b y a mechanical equalizing slide in the housing (see cutaway dr awings). the springs only function is to return the barrels to a fully extended position when ther e is no work contact. maximum conductivity is maintained through sturdy copperalloy working parts. spacing can vary up to 4 inches, using tuffaloy bent offset tips in equa-press holders having the standard barrel spacing of two inches (shown). barrel spacing up to six inches is available as semi- standard (see price list). these are drilled to order from stock components. to order you must give the barrel spacing desired, along with the item number (from table). equa-press holders are made in two mounting styles: platen models to mount directly to the platen on press- type welding machines, and shank models for r ocker arm machines. all are available in two designs: the standard and the short (close-coupled) type. the short design is internally flood-cooled and takes up less space in the welder. equa-press holders can be used with forces up to 1500 lbs. equa-press tm dual tip holders u.s. pat. no. 2,979,599 canada pat. 637470 note: for best results, position the holder so that a line drawn through the electrode centers is at, or nearly at, right angles to the direction of the welder arms. otherwise, the magnetic field between the arms can cause an excess of current to flow through the inboard electrode. 36 tuffaloy multiple welding
shank diameter description part no. 1 4020 350-4020 1-1/4 4021 350-4021 1-1/2 4022 350-4022 shank a style diameter description* tip spacing (inches) range (inches) 4body 1 4030 1-1/4 to 2-7/8 1-1/4 4031 1-1/4 to 2-7/8 1-1/2 4032 1-1/4 to 2-7/8 8body 1 8030 3 to 6 1-1/4 8031 3 to 6 1-1/2 8032 3 to 6 lower electrodes standard lower holder - 2spacing 5 rw special lower electrodes in this drawing, two studs ar e pr ojection welded in each welder stroke, using an equa-press dual holder over a pair of studwelding electrodes held in pm- style holders. here, four spot welds are made simultaneously on a corrugated part. an equa- press dual holder is used to hold two teeter-tip dual tip adapters. a case history: projection welding brackets to automotive frame assemblies is twice as fast with an equa-press dual tip holder. lower welding fixture acts as an inspection device, so warped parts are disco vered before welding. inspection time and scrap loss are both reduced. a case history: joining a piece of metal to itself is always tough. this job was done with an equa-press holder - two at a time. lower clamp faces, carrying current, contact parts near the weld areas to avoid curr ent bypassing weld projections. two standard swivel tips make four welds, two per part. a case history: dual spot welding of panelled wall sections reduced welding costs enough to justify buying welding machine to do the job in-plant. equa-press holder with 5-inch spacing, and special (but simple) tooling to provide two offset tip adapters and matching holders were used. electrodes are standar d tuffcap caps. lower holders and electrodes for use with equa-press holder a lower, fixed, dual tip holder is offered for use with equa-press holders. like the equa-press, it has a standard two-inch tip spacing and helps make two welds at once, precisely alike. the standard trans-verse bar electrode shown is used when work geometry doesn require tips on the lower side. they are water-cooled. * when ordering specify center distance and either 4r w or 5rw sockets lower holder shank diameter description part no. 1 4030 350-4030 1-1/4 4031 350-4031 1-1/2 4032 350-4032 5 lower electrode 4 1-1/2 sq. 4 lower electrode 4 2 a 5 rw 4 rw-special 5rw-special body is 1 thick 37 tuffaloy multiple welding
mounting style descrip- part tion no. 1-in. shank 4040 350-4040 1-1/4-in. shank 4041 350-4041 1-1/2-in. shank 4042 350-4042 platen 4043 350-4043 shank descrip- part dia. tion no. 1 4025 350-4025 1-1/4 4026 350-4026 1-1/2 4027 350-4027 trispacer holder lower electr ode symbols trispacer tm triple tip holder u .s. pat. no. 3,558,848 the trispacer tip holder will make three spot welds at one time, automatically splitting the current and the pressure equally between the three tips. in doing so, it compensates for variations in work thicknesses and electrode wear-up to 3/16-in. the three tip-holder barrels (#5 rw) are equidistant from one another, all falling on a 1-5/8-in. diameter circle (in the standard model shown). using straight tips the weld pattern would form an equilateral triangle. however, the weld pattern can be widely varied by using standard or special bent tips. in fact, the three welds can be made in a straight line. the trispacer holder works in the same simple, mechanical way as the equa-press holder: the tip- holding barrels have a limited up-and-down movement, to accommodate work conditions, and are adjusted to deliver equal pressure by the cone-shaped equalizing device in the housing. ali curr ent-carr ying parts are made of rwma copper alloys. it is made in two styles: to mount directly to the platen of press-type welders, and with shanks to fit in welder arms. lower electrode a simple, water-cooled lower electrode is made for use with the trispacer holder. its three-inch-diameter face makes it usable with any weld pattern that may be developed for the t rispacer . it comes in three shank diameter models. diagram indicates the wide range of weld patterns which can be made with the trispacer by using straight, standard bent or special bent tips. maximum triangle size straight-tip triangle size m inimum triangle size maximum straight-line spacing 1-7/8 3 1/2 4 2 5 rw taper platen dimensions 1/2 x 3-1/2 x 7 3 dia. 38 tuffaloy multiple welding
spring 1/8-in. 1/4-in. 3/8-in. 1/2-in. type compression compression compression compression m (300 lbs. max.) 140 200 250 300 mh (680 lbs. max.) 310 440 560 680 h (1300 lbs. max.) 600 840 1070 1300 300 lbs max. 680 lbs. max. 1300 lbs. max. (m spring) (mh spring) (h spring) descrip- part descrip- part descrip- part tion no. tion no. tion no. 1shank 4620 350-4620 4621 350-4621 4622 350-4622 1-1/4shank 4623 350-4623 4624 350-4624 4625 350-4625 1-1/2shank 4626 350-4626 4627 350-4627 4628 350-4628 platen-mtd. 4629 350-4629 4630 350-4630 4631 350-4631 fast-follow-up for ce chart (lbs.) u.s. pat. no. 3,632,958 canada pat. no. 902,189 tuffaloy fast-follow-up (low inertia) holders solve the pr oblem of maintaining adequate weld pressure on rapidly c ollapsing projection welds-with fewer set-up problems and reduced maintenance. t hese holders can be set to deliver fast-follow-up forces of from 140 to 1300 pounds, a range covering 90% of all projection welding operations. they are compact, water cooled, and easy to maintain. plus features of the tuffaloy fast-follow-up holder include: (1) wider range of pressures than any competitive make (2) no flexible shunt-a common cause of holder failure (3) use of standard, unmodified die springs, so if you need a spring of different strength, its easily available (4) spring forces available are clearly indicated, so its easy to set up for a specific force (5) three shank sizes, or it can be platen- mounted-the only fast-follow-up holder that can (6) extremely low height permits use where larger units can be used. tuffaloy fast-follow-up holders can be used to limit the weld pressure of any spot welding machine regardless of cylinder size or air pressure. this is better than reducing air pressure, which slows the return stroke and retards production. current flow follows dashed arrow thr ough the outer body, two split contact rings, tapered tip socket, and to the electrode. for every one-eighth of an inch that a fast-follow-up is compressed when setting up , a kno wn amount of force is provided, to quickly follow up any r eduction in work thickness. example: at position b, a type mh spring would delivery 310 lb, at c, 440 lb, etc. mounting style a no external compression b compression 1 mark c compression 2 marks d compression 3 marks tuffaloy fast-follow-up holders 39
square hexagonal round rect angular tuffaloy tuffaloy tuffaloy 88 77 55 class 1 alloy class 2 alloy class 3 alloy item no. item no. item no. 1/8 .048 431-0125 3/16 .106 421-0187 431-0187 1/4 .189 421-0250 431-0250 5/16 .296 421-0313 431-0313 3/8 .426 421-0375 431-0375 1/2 .758 421-0500 431-0500 9/16 .959 421-0562 431-0562 5/8 1.184 411-0625 421-0622 431-0625 21/32 1.82 421-0656 3/4 1.704 411-0750 421-0748 431-0750 7/8 2.32 411-0875 421-0872 431-0875 1 3.03 421-1000 431-1000 1-1/8 3.84 421-1125 431-1125 1-1/4 4.74 421-1250 431-1240 1-3/8 5.74 421-1375 431-1375 1-1/2 6.82 421-1500 431-1500 1-5/8 7.97 431-1625 1-3/4 9.28 421-1750 431-1750 2 12.12 421-2000 431-2000 2-1/8 13.62 431-2125 2-1/4 15.40 421-2250 431-2250 2-1/2 18.97 421-2500 431-2500 2-3/4 23.00 421-2750 3 27.15 421-3000 431-3000 3-1/4 32.05 431-3250 3-1/2 37.18 431-3500 3/8 .472 422-0375 5/8 1.31 422-0625 3/4 2.18 422-0750 432-0750 7/8 2.56 422-0875 432-0875 1 3.35 422-1000 432-1000 1-1/8 4.24 422-1125 432-1125 1-1/4 5.25 422-1250 432-1250 1-1/2 7.55 422-1500 432-1500 1/4 .24 433-0250 3/8 .54 433-0375 1/2 .96 423-0500 433-0500 5/8 1.56 423-0625 433-0625 3/4 2.16 423-0750 433-0750 1 3.84 423-1000 433-1000 1-1/4 6.00 423-1250 433-1250 1-1/2 8.64 423-1500 433-1500 1-3/4 11.83 423-1750 2 15.46 423-2000 433-2000 tuffaloy tuffaloy 77 55 class 2 alloy class 3 alloy item no. item no. 1/4 x 1/2 .484 434-0205 1/4 x 3/4 .727 434-0207 1/4 x 1 .96 424-0210 434-0210 1/4 x 1-1/4 1.20 424-0212 1/4 x 1-1/2 1.44 424-0215 434-0215 1/4 x 2 1.92 424-0220 434-0220 3/8 x 5/8 .900 434-0306 3/8 x 314 1.08 424-0307 434-0307 3/8 x 1 1.44 424-0310 434-0310 3/8 x 1-1/2 2.16 424-0315 3/8 x 2 2.88 434-0320 1/2 x 3/4 1.44 424-0507 434-0507 1/2 x 1 1.92 424-0510 434-0510 1/2 x 1-1/4 2.40 434-0512 1/2 x 1-1/2 2.138 424-0515 434-0515 1/2 x 2 3.134 424-0520 434-0520 1/2 x 2-1/2 4.133 424-0525 434-0525 1/2 x 3 5.81 424-0530 434-0530 5/8 x 3/4 1.80 424-0607 434-0607 5/8 x 1 2.40 424-0610 434-0610 5/8 x 1-1/2 3.60 424-0615 434-0615 5/8 x 2 4.85 424-0620 434-0620 5/8 x 3 7.27 424-0630 5/8 x 4 9.60 424-0640 3/4 x 1 2.88 424-0710 434-0710 3/4 x 1-1/4 3.64 424-0712 434-0712 3/4 x 1-1/2 4.32 424-0715 434-0715 3/4 x 2 5.72 424-0720 434-0720 3/4 x 2-1/4 6.48 434-0722 3/4 x 2-1/2 7.20 424-0725 434-0725 3/4 x 3 8.64 424-0730 1 x 1-1/4 4.85 424-1012 434-1012 1 x 1-1/2 5.76 424-1015 434-1015 1 x 2 7.68 424-1020 434-1020 1 x 2-1/2 9.70 424-1025 434-1025 1 x 2-3/4 10.56 424-1027 1 x 3 11.55 424-1030 434-1030 1-1/4 x 1-1/2 7.25 424-1215 1-1/4 x 1-3/4 8.40 424-1217 1-1/4 x 2 9.60 424-1220 1-1/4 x 2-1/2 12.06 424-1225 1-1/2 x 1-3/4 10.09 424-1517 1-1/2 x 2 11.60 424-1520 434-1520 1-1/2 x 3 17.28 424-1530 434-1530 2 x 3-1/4 25.15 424-2032 2 x 3-3/4 29.05 424-2037 tuffaloy extruded bar stock is used for fabricating special electrodes, platens, adapters, and other conductive parts. round bar is available in all three alloy classes (1, 2 & 3). the other shapes are made in class 2 and 3 alloy. physical properties are superior to those shown on page 45. bar stock is priced per pound in random mill lengths, from 8 to 12 feet. additional charges are made depending on specific weights and lengths ordered. see the tuffaloy price list. weight pounds per foot size in inches weight pounds per foot size in inches tuffaloy bar stock 40
stronger, generally harder, and having less conductivity, t he refractory metal compositions include copper-tungsten (classes 10-11), tungsten (class 13) and molybdenum (class 14) alloys. the bars and inserts listed below are made in the following rwma group b alloys: class 10 (tuffaloy 1w), class 11 (tuffaloy 10w), and class 12 (tuffaloy 20w). bars and inserts of class 13 (tuffaloy 100w) and class 14 (tuffaloy 100m), as well as special sizes and shapes, are priced on request. copper tungsten round bars eight inches long, available in the following diameters: from 1/8to 2? copper tungsten rectangular and square bars eight inches long, available in following dimensions: widths from 1/8to 2?nd thicknesses from 1/8to 1? copper tungsten round inserts available in following dimensions: diameters from 1/8to 2?nd thicknesses from 1/4to 1? tuf faloy forgings are used to make seam welder wheels and shafts, butt and flash welder dies, and welder arms and platens. forgings are superior to castings in physical properties and in absence of porosity. they are available in tuf faloy 88, 77 and 55 (class 1, 2 and 3 alloy). all are readily machinable. when ordering specify whether forging is to be as-forged or finish machined. regardless of how it is wanted always order by giving finish dimensions. tuffaloy refractory metal compositions 41 tuffaloy forgings
mcm o.d. lug w idth lug thickness rating (approx.) a b 600 1-5/8 1-3/8 .50 750 1-3/4 1-3/8 .60 1000 2 1-1/2 .70 1200 2-1/8 1-1/2 .82 1500 2-1/4 1-1/2 .99 dimensions, inches laminated copper shunts are made to your size and shape specifications. high conductivity electrolytic copper strip is used, and terminal clips are riveted in place. how to order give the following information: type (c, f, or j) outside length (ol) width (w) thickness (less clip) (t) hole pattern (specify by letter code) hole location (x, y, z values) hole diameter air -cooled jumper cables ar e flexible, high-conductivity copper conductors with insulativ e sleev es. they are made in lengths to suit your needs. how to order giv e the following information: conductor rating (mcm) length between holes terminal orientation style holes ar e 1 7/3 2 unless otherwise specified. hole pa ttern a hole pa ttern b hole pa ttern c hole pa ttern e type c type f type j terminal orientation tuffaloy shunts and jumpers 42
male cap extractor has long lever handles for easier cap removal. in two dual-size models: ex-45 and ex-56. female cap extractors are made for three tuffcap shank sizes: models ex-4f, ex-5f, and ex-6f. tip socket reamers h ole in reamer center permits water tube entry; no need to dismantle holder. 4 rw; part no. 601-0004; 5 rw, part no. 601-0005; 6 rw, part no. 601-0006; 7 rw, part no. 601-0007. tip dressing tool to remove mushroomed nose material on a pair of tips of 4 or 5 rw size, having pointed or dome noses. other nose design dressers on special order. dresser, part no. 601-0102; dresser cutter, part no. 601-0103. radius tip file t o r estor e original contours of welding tips use this two-inch radius file. part no. 601-0120. welding tip extractors tuffcap socket reamers to ream or dress sockets to hold male caps. 4 rw, part no. 6 01-0014; 5 rw, part no. 601-0015; 6 rw, part no. 6010016. quick-connect couplings with automatic shut-off use these couplings to make up efficient, trouble free coolant systems. any plug shown will mate with any socket shown. always put the socket on the upstream side of a connection. its built-in valve will automatically close upon disconnection. tuffcap extractors male caps, 4 & 5 rw, ex-45, part no. 601-0240 male caps, 5 & 6 rw, ex-56, part no. 601-0242 female caps, 4 rw, ex-41f, part no. 601-0220 female caps, 5 rw, ex-5f, part no. 601-0221 female caps, 6 rw, ex-6f, part no. 601-0222 no. 4 rw, ex-1, part no. 601-0201 no. 5 rw , ex-2, part no. 601-0202 no. 4 rw and 5 rw at opposite ends, ex-3, par t no. 601-0203 lar ge: ex-10-a, par t no. 601-0231 tip file 1/8npt female plug part no. 601-0300 1/8npt male plug part no. 601-0301 1/4npt male plug part no. 601-0302 1/4npt male plug part no. 601-0303 3/8npt hose plug part no. 601-0309 1/8npt female socket part no. 601-0314 1/8npt male socket part no. 601-0315 1/4npt female socket part no. 601-0316 1/4npt male socket part no. 601-0317 3/8npt hose socket part no. 601-0320 43 tuffaloy accessories
digital-hydraulic standard-hydraulic high-capacity hydraulic d igital-electronic we offer one of the broadest product lines available today tuffaloy supplies a broad range of weld force gauges, available with accuracies from 0.5% for digital-electronic gauges; to 2% accuracy for the digital-hydraulic which has a digital output driven by hydraulics; to our standard hydraulic models with 2%-3% accur acy . a ll ar e available in english and metric readouts. our digital-electronic gauge supplies the highest accuracy (0.5% for 9 5% of the gauges r ange). the gauge has lar ge lcd readouts with peak-hold capabilities. all functions ar e electronic which pr ev ents variations caused by flexing. the digital-hydraulic delivers better accur acy than standar d hydr aulic gauges but at a lower price than all- digital models. the peak-hold feature allo ws for reading variable forces, which ar e common in r esistance welding machinery. gauges maintain an accuracy of 1% for 30% to 90% of the gauge s r ange. tuffaloys standard hydraulic gauges ar e the lo w cost method for obtaining gener al force measur ements. these gauges ar e available in a standard block style, with extensions. siz es r ange from 600 lb . up to 1 0 tons with accuracy of 2% at the mean and 3% outside of mean for 70% of the gauge s r ange. high-accuracy weld force gauges available from tuffaloy tuffaloy weld force gauges 44
st andard ga uge da t a description features m aximum increment opening extension item reading every required length number 0-1000 lbs/ 1 lb 601-8010md 0-454 kg 1 kg 1/4 10 601-8045md-kg 0-3000 lbs/ 1 lb 601-8300md 0-1133 kg 1 kg 1/2 10 601-8136md-kg 0-5000 lbs/ 1 lb 601-8500md 0-2270 kg 1 kg 1.1 10 601-8227md-kg 0-10,000 lbs/ 1 lb 601-8100md 0-2270 kg 1 kg 1.1 10 601-9453md-kg 0-1361 kg 1 kg 3/4 C 601-1361d 0-3000 lbs 1 lb 3/4 C 601-3000d 0-5000 lbs 1 lb 3/4 C 601-5000d 0-10,000 lbs 1 lb 3/4 C 601-9999d 0-3000 lbs 1 lb 3/4 12 601-3000d-12s 0-600 lbs 10 lb 3/4 C 601-8006 0-1000 lbs 20 lb 3/4 C 601-8010 0-2000 lbs 50 lb 3/4 C 601-8020 0-2000 lbs 50 lb 3/4 12 601-8020-12 0-3000 lbs 20 lb 3/4 C 601-8030 0-3000 lbs 20 lb 3/4 12 601-8030-12 0-5000 lbs 100 lb 3/4 C 601-5000 0-6000 lbs 50 lb 3/4 C 601-6000 0-6000 lbs 50 lb 3/4 18 601-6000-18 0-10,000 lbs 100 lb 3/4 C 601-8100 0-5000 kg 50 kg 3/4 C 601-8101 0-20,000 lbs 50 lb 1-3/4 C 601-20000 digital-electronic weld probe standard- hydraulic* high- capacity hydraulic* digital- hydraulic* * h ydraulic gauges should be selected to be used near mid-range. ? analog output ? auto shut-off ? no-weld setting- not required ? accuracy 0.5% over full range ? accuracy 2% ? nist traceable certification ? dual reading, lbs and kg ? accuracy 3% ? metric equivalent available tuffaloy weld force gauges 45
recommended uses of resist ance welding ma terials group a copper-base alloys rwma class 1 alloy ?tuffaloy 88 zirconium-copper, suited to welding aluminum and magnesium alloys, coated materials, brass and bronze. class 1 alloy is superior to pure copper as an electrode material and is recommended as a general purpose material for resistance welding use. it may be used for spot welding electrodes, seam welding wheels and welding fixture components. it is not heat treatable. rwma class 2 alloy tuffaloy 77 chromium-copper, suited to welding cold- and hot-rolled steels, stainless steel, and low-conductivity brasses and bronzes. class 2 alloy is a superior resistance welding electrode material, recommended for high-production operations. it is used for welding electrodes, projection welding electrodes, seam welding shafts and bearings, flash and butt welding electrodes, and current-carrying structural components. available in forms for use as welding gun arms, welding platens and secondary-circuit structural members. it is heat treatable. tuffaloy z zirconium-chromium-copper is suited to welding galvanized steel and other metallic-coated steel. this is a specially heat-treated alloy which meets the minimum electrical conductivity and hardness specifications of class 2 alloy. rwma class 3 alloy ?tuffaloy 55 and 55a beryllium-nickel-copper (55) are suited to welding steels having high electrical resistance, such as stainless steel. nickel-copper (55a) is a beryllium-free alloy with properties similar to tuffaloy 55. class 3 alloy is recommended for projection welding electrodes, and flash and butt welding electrodes. with its higher strength it is also used on highly-stressed current-carrying parts such as electrode shanks and heavy-duty electrode holders. it is heat treatable. rwma class 4 alloy ?tuffaloy 44 b eryllium-copper has extremely high hardness, and is recommended for projection, flash and butt welding electrodes. it has lower conductivity than class 3 alloy but it is harder and more wear resistant. it should be considered where there is concern with high pressur e density and severe wear, but where heating, due to its low conductivity, is not excessive. it is used frequently in the form of inserts, tooling facings, and seam welder bushings. it is available in the annealed condition which is mor e readily machined and then subsequently heat treated. group b refractory metal compositions rwma class 10 ?tuffaloy 1w tungsten 55% Ccopper 45%, suited for facings and inserts for projection welding electrodes and flash and butt welding electrodes. it is recommended wher e (relativ ely) high electrical conductivity and some degree of malleability is desired. rwma class 11 ?tuffaloy 10w tungste n 75% Ccopper 25%, suited to similar applications as class 10, and for facing on electrode forming electrodes. it is harder than class 10, and is for general use in projection welding electrodes. rwma class 12 ?tuffaloy 20w tungsten 80% Ccopper 20%, suited for electro-forming and electro-forging facings, and for electrode facings used to upset studs and rivets. a material for heavy-duty projection welding electrodes. rwma cl ass 13 ?tuffaloy 100w (pure tungsten) rwma class 14 ?tuffaloy 100m (pure molybdenum) class 1 3 & 14 materials are used primarily for welding or electro-brazing non-ferrous metals having relatively high electrical conductivity. they are suited to cross-wire welding of copper and brass, and for welding copper wire braid to brass or bronze terminals. special set-ups and procedures are required. tuffaloy welding data 46
read block under metal t o be welded to weld similar metals to weld dissimilar metals legend rwma recommended electrode materials for spot welding using conventional spot welding methods weldability a-excellent b-good electrodes, rwma specifications i = gr oup a, class 1 - tuf f aloy 88 ii = gr oup a, class 2 - tuffaloy 77 & tuffaloy z iii = gr oup a, class 3 - tuffaloy 55 materials indicated in circles are second choice, example ii special information 1 - s pecial conditions required 2 - good pr actice r ecommends cleaning befor e welding 3 - if plating is heavy , weld strength is questionable. data based on r esistance welding equipment standards, bulletin 16, a publication of the resistance welder manufacturers association. bl ock interpreta tion tin terne galvanized cadmium chrome stainless scaly c.r. steel ferrous plate plate iron zinc plate plate steel h.r. h.r. steel steel steel plate steel steel 18-8 type steel (clean) b i a i a i ii b i a ii a iii ii b i ii a ii i 3 i 3 i ii 3 i 3 ii 3 iii ii i ii 2 ii cold rolled steel hot rolled steel, clean tin plate steel terne plate steel galvanized ir on zinc plate cadmium plate steel chrome plate steel nickel silicon aluminum a lloys brass phosphor bronze non-ferrous aluminum alloys cupro nickel nickel monel yellow bronze everdur dura- nickel silver nichome 25-40% grade olympic luminum (high zinc a, c & d duronze res.) herculoy b i ii b i ii a ii b ii a ii a ii b ii a b ii a b ii i ii 2 i ii 2 ii ii ii ii ii ii ii stainless chrome cadmium gal- terne tin ferrous steel plate plate vanized plate plate alloys 18-8 type steel steel iron steel steel a ii iii a ii b ii b i a i ii b i iii ii 3 ii 3 ii 3 ii 3 ii 3 b ii iii b ii b i ii b i b i ii i i 3 i 3 i 3 i 3 b ii b ii b i ii b i i 3 i 3 i 3 i 3 b ii b ii b i i 3 i 3 i 3 b ii b ii i 3 i 3 a iii ii ii 3 weld- electrodes ability against electrodes special against information silicon bronze everdur-olympic bronze-herculoy non-ferrous nickel phosphor silicon yellow nickel alloys alloys nickel bronze bronze brass silver b ii b ii b ii b ii b ii b ii ii ii ii ii ii ii b ii b ii b ii a ii b ii ii ii ii ii ii b ii b ii b ii b ii ii 1 ii ii 1 ii a ii b ii ii ii b ii b ii iii ii 1 ii iii nickel alloys stainless steel 18-8 t ype nickel silver cupr o nickel aluminum alloys duraluminum alum- inum b i ii i ii 2 47 tuffaloy welding data
group a copper base alloys group b refractory metal compositions proportional ultimate elongation tuffaloy limit hardness conductivity tensile percent class number tension rockwell percent strength in 2or 4 p . s. i. i. a. c. s. p. s. i. diameter round rods 1 88 17,500 65-b 80 60,000 13 up to 1dia. 2 77 35,000 75-b 75 65,000 13 3 55 50,000 90-b 45 100,000 9 1 88 15,000 60-b 80 55,000 14 1to 2?ia. 2 77 30,000 70-b 75 59,000 13 3 55 50,000 90-b 45 100,000 9 1 88 15,000 55-b 80 50,000 15 2to 3?ia. 2 77 25,000 65-8 75 55,000 13 3 55 50,000 90-b 45 95,000 9 bars squar e 1 88 20,000 55-b 80 60,000 13 rectangular 2 77 35,000 70-b 75 65,000 13 hexagon 3 55 50,000 90-b 45 100,000 9 up to 1thick 1 88 15,000 50-b 80 50,000 14 over 1thick 2 77 25,000 65-8 75 55,000 13 3 55 50,000 90-b 45 100,000 9 1 88 20,000 55-8 80 45,000 12 forgings 2 77 22,000 65-b 75 55,000 13 up to 1 3 55 50,000 90-b 45 94,000 9 1 88 15,000 50-b 80 40,000 13 1to 2 2 77 21,000 65-b 75 55,000 13 3 55 50,000 90-b 45 94,000 9 1 88 15,000 50-b 80 40,000 C over 2 2 77 20,000 65-b 75 55,000 12 3 55 50,000 90-b 45 94,000 5 all sizes 4 44 85,000 33-c 20 140,000 .5 2 77 20,000 55-8 70 45,000 12 castings 3 55 45,000 90-b 45 85,000 5 all sizes 4 44 60,000 33-c 18 90,000 .5 5 66 12 to 16,000 65 to 85-b 10 to 15 65 to 75,000 2 to 10 10 1w 72-b 35 rods, 11 10w 94-b 28 bars & 12 20w 98-b 27 inserts 13 100w 69-a 30 14 100m 85-b 30 135,000 ultimate 160,000 compression 170,000 strength 200,000 p. s. i. minimum physical properties for rwma alloys published standards of the resistance welder manufacturers association } 48 tuffaloy welding data
thickness electrode net weld welding mini- mini- dia- thickness ?f diameter elec- time current mum mum meter minimum shear ?f thinnest trode (single (approx.) con- weld of strength thinnest outside force im- tacting spacing fused piece piece pulse) over- zone lap lbs. tensile tensile strength strength cycles below 70000 (60 70000 psi per in. psi and inches inches lbs. sec.) amps inches inches approx. above inches 0.010 3/8 200 4 4000 3/8 1/4 0.10 130 180 0.010 0.021 3/8 300 6 6500 7/16 3/8 0.13 320 440 0.021 0.031 3/8 400 8 6600 7/16 1/2 0.16 570 800 0.031 0.040 1/2 500 10 9500 1/2 3/4 0.19 920 1200 0.040 0.050 1/2 650 12 10500 9/16 7/8 0.22 1350 C 0.050 0.062 1/2 800 14 12000 5/8 1 0.25 1850 C 0.062 0,078 5/8 1100 17 14000 11/16 1-1/4 0.29 2700 C 0.078 0.094 5/8 1300 20 15500 3/4 1-1/2 0.31 3450 C 0.094 0.109 5/8 1600 25 17500 15/16 1-5/8 0.32 4150 C 0.109 0.125 7/8 1800 26 18000 7/8 1-3/4 0.33 5000 C 0.125 thickness electrode net weid welding minimum (of thinnest diameter electrode time current overlap piece) force (approx.) inches inches pounds cycles amps. inches 0.030 1/2 475 11 10,500 1/2 0.035 1/2 550 12 11,000 9/6 0.040 5/8 625 13 12,500 5/8 0.050 5/8 840 18 14,000 11/16 0.060 5/8 1050 23 15,500 3/4 0.075 3/4 1400 28 19,500 7/8 0.093 3/4 1800 34 24,000 1 0.109 3/4 2200 39 28,500 1-1/4 thickness diameter height of minimum shear str ength diameter minimum of thinnest of projection (single projecting only) of fused contacting outside piece projection zone overlap (nominal) pounds minimum (at weld tensile tensile tensile interface strength strength strength below 70000 150000 70000 up to psi psi 150000 and inches inches inches psi above inches inches 0.010 0.055 0.015 130 180 250 0.112 1/8 0.012 0.055 0.015 170 220 330 0.112 1/8 0.014 0.055 0.015 200 280 380 0.11 2 1/8 0.016 0.067 0,017 240 330 450 0.112 5/32 0.021 0.067 0.017 320 440 600 0.140 5/32 0.025 0.081 0.020 450 600 820 0.140 3/16 0.031 0.094 0.022 635 850 1100 0.169 7/32 0.034 0.094 0.022 790 1000 1300 0.169 7/32 0.044 0.119 0.028 920 1300 2000 0.169 9/32 0.050 0.119 0.028 1350 1700 2400 0.225 9/32 0.062 0.156 0.035 1950 2250 3400 0.225 3/8 0.070 0.156 0.035 2300 2800 4200 0.281 3/8 0.078 0.187 0.041 2700 3200 4800 0.281 7/16 0.094 0.218 0.048 3450 4000 6100 0.281 1/2 0.109 0.250 0,054 4150 5000 7000 0.338 5/8 0.125 0.281 0.060 4800 5700 8000 0.338 11/16 0.140 0.312 0.066 6000 C C 7/16 3/4 0.156 0.343 0.072 7500 C C 1/2 13/16 0.171 0.375 0,078 8500 C C 9/16 7/8 0,187 0.406 0.085 10000 C C 9/16 15/16 0.203 0.437 0,091 12000 C C 5/8 1 0.250 0.531 0.110 15000 C C 11/16 1-1/4 projection welding schedule guide for one projection: for more than one projection: current = 1t + .045 x 100,000 amps current = 1t + .045 x 100,000 + 30% for each additional projection time = 2t x 100 hertz (cycles) time = 2t x 100 hertz (cycles) = 2t x 6,000 lbs. pressure = 2t x 6,000 + 50% for each additional projection spot welding low carbon steel 1. type of steel: sae 1010 2. material should be free from scale, oxides, paint, grease and oil. 3. welding conditions determined by thickness tof thinnest outside piece. 4. data for total thickness of pile-up not exceeding 4 t recommended maximum ratio between two thicknesses: 3 to 1. 5. electrode material: class 2 (tuffaloy 77) 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. spot welding galvanized steel 1. type of galvanized: 1.25 oz/ft 2 nominal. 2. material should be free from dirt, paint, grease and oil. 3. w elding conditions determined b y thinnest of two pieces only. schedule is good for thickness ratios up to 2:1. 4. electrode material: class 1 or 2 (tuffaloy 88 or 77). 5. electrode nose design: dome or truncated cone. (fr om international lead, zinc r esear ch or ganization, inc.) projection welding data for low carbon and stainless steel 1. types of steel: low-carbon-sae 1010 stainless-types 309, 310, 316, 317, 321, 347 and 349. (non-har denable: max. carbon content 0.15%) 2. material should be free from scale, oxides, paint, grease and oil. 3. siz e of projection normally determined b y thickness of thinner piece, and projection should be on thicker piece where possible. 4. data based on thickness of thinner sheet, and for two thicknesses only. 5. contacting overlap does not include any radii from forming, etc. 6. weld should be located in center of overlap. 7. pr ojection should be made on piece of higher conductivity when dissimilar metals ar e w elded. 8. for diameter of projection ? tolerance of 0.003 in. in material up to and including 0.050 in. in thickness and 0.007 in. in material over 0.050 in. in thickness may be allowed. 9. for height of projection ? tolerance of 0.002 in. in material up to and including 0.050 in. in thickness and 0.005 in. in material over 0.050 in. in thickness may be allowed. tuffaloy helpful suggestions 49
to determine spot welding schedule current = 2t x 100,000 = amperes time = 2t x 100 = cycles pressure = 2t x 6000 (lb) = force required (lb) t = thickness of the thinnest piece approxima te pressure exerted by air cylinder size diameter cylinder area sq. inches 4 = 12.5 x = 5 = 19.5 x = 6 = 28.0 x = 8 = 50.0 x = resistance welding machine setup gage manufacturers gage manufacturers gage manufacturers no. standard no. standard no. standard 3 0.2391 12 0.1046 22 0.0299 4 0.2242 13 0.0897 23 0.0269 5 0.2092 14 0.0747 24 0.0239 6 0.1943 15 0.0673 25 0.0209 7 0.1793 16 0.0598 26 0.0179 8 0.1644 17 0,0538 27 0.0164 9 0.1495 18 0.0478 28 0.0149 10 0.1345 19 0.0418 29 0.0135 11 0.1196 20 0.0359 30 0.0120 21 0.0329 standard gage chart 1. use standard tuffaloy electrodes with tuffaloy ejector type, self-adjusting tube, water-cooled electrode holders wherever possible. avoid special or irregular shapes for lowest cost. 2. use ample cold cooling water as close as pr actical to the welding contact surface, properly cir culated at a minimum of 30-psi pressure, and supplied at a rate of at least 1-1/2 gallons per minute. 3. be sure to select the proper type and size of electr ode, taking into consideration electrode pressure, contact area of electrode, gauge, and natur e of material to be welded. consult the rwma manual* or your tuffaloy field engineer regarding recommended practices. overloading as well as overheating shortens electrode life. 4. good welds depend upon properly maintained electrodes which assure an accurate surface contact. keep tapers clean and dress electrode faces with lathe, emery paddle or fine file. use castor oil or graphite grease to facilitate tip removal, and avoid application of insulators such as teflon tape and other materials. electrode life savers many factors affecting electrode cost and useful electrode life are briefly outlined below. part to be welded lay out the part for resistance welding. designing engineer, welding engineer and production man in charge of welding s hould cooperate in securing a better product at lowest cost. correct design permits the use of standard straight electrodes: or standard offset or standard angular holders if the straight a pproach is not possible. special shaped electrodes cost more, and the difficulty of cooling the electrode is amplified. single spot, multiple spot, projection, or other method may be accurately chosen to achieve lowest cost. consult the r.w.m.a manual.* material to be welded the weldability of the materials can be determined by consulting your material supplier, and by reviewing recommendations covered in the r.w.m.a manual.* surface conditions, rust, oil, dirt, and, on many articles, oxide film and ev en handling marks hav e a decided effect on weld quality. cleaning may have to be a part of the welding job in some cases. welding eq uipment and control a welding machine of reputable quality purchased for a par ticular application will be correctly designed both electrically and mechanically, and will be supplied the correct control equipment and electrodes for the work. on machine change-overs make sur e of adequate electrical and mechanical capacity, and see that the necessary controls ar e pro vided. consult us when redesigning or revising y our choice of electrodes. * r esistance welding manual, published by the resistance welder manufactur ers association. t he rwma tip numbering system has generally replaced the old morse taper numbers with new wnumbers, and has a dded two new sizes, as the chart illustrates. thickness in decimals of an i nch welder guage pressure electrode force pressure 50 tuffaloy helpful suggestions
tuff al o y helpful suggestions 51 expulsion at weld interface ? shor t squeeze time ? low weld force ? dirty Cscaly material ? poor fit up ? insufficient edge distance surface expulsion/ electrode sticking ? short squeeze time ? long weld time ? short hold time ? low weld force ? high weld current ? dir ty Cscaly material electrode mushrooming ? insufficient cooling ? l ow weld force ? high weld current ? small electrode face area ? long weld time ? w elder head impacts w ork low weld strength ? shor t weld time ? low weld force ? low weld current ? small electrode face area ? poor heat balance ? welds too close together excessive weld indentation ? l ong weld time ? high weld force ? high weld current ? poor fit up ? welder head impacts work internal cracks in weld nugget ? shor t hold time ? low weld force ? dirty Cscaly material ? metallurgy of material welded ? poor head follow up displaced weld nugget ? electr ode misalignment ? poor heat balance ? poor fit up cracks in parent material ? high w eld force ? insufficient cooling ? metallur gy of material welded problem solving ? use standard rwma design electrodes whenever possible. use the rwma recommended electrode material for the part being welded. keep the electrodes aligned normal to the working face. only use offset electrodes or weld at an angel when nothing else will work. ? check the water deflector tubes each time you install electrodes. they should be within one quarter inch of the bottom of the water hole of the electr ode. ? confirm there is water flow from the electrodes, transformer, control and other cooled components before welding. ? always use the proper size water hose, if removed check for obstructions that might impede flow. ? when a set up will not be used for a period of time r emove the electrodes from the holders to avoid freezing into the holder due to corr osion. ? use fine emer y cloth to dr ess electrode faces. if wear is excessive remove from the machine and dress in lathe or other controlled machine. dressing electrodes with files is not recommended because alignment and consistency are not possible with this manual method. ? if the use of a hammer is necessary on resistance w elding machine or its components, use rubber , plastic, brass, raw-hide or other soft material. never use a steel hammer. ? if a water leak is found repair as soon as possible, or report it to the appropriate maintenance personnel. ? check all mechanical connections in the secondary connections. check all shunts and cables for damage, replace as needed. ? perform maintenance to resistance welding equipment as outlined in rwma bulletin 14. ? k eep in mind that sparks/expulsion ar e an indication that something is not right at the weld. it could be current, force, time, alignment and many other factors. take time, check your set up for variance from the desir ed settings. expulsion can be dangerous and could also result in questionable product. resistance welding helpful hints
tuff al o y helpful suggestions 52 do dons resistance welding ? use the rwma recommended electrode material for the job you are running. ? use rwma standard electrodes whenever possible. ? use the appropriate electrode diameter for the material being welded. ? use open sight drains or have water flow gauges on out bound side to easily confirm water flo w. ? connect the water inlet hose to the proper holder inlet to insure water flows through the center cooling tube first. ? recommended water flow for the electrodes is 1.5 gallons per minute of cold water. ? insure that the water tube extends within 0.25of the bottom of the electrode water hole. ? adjust the water tube position when changing to another length electrode. ? check water tube ends to insur e they ar e not damaged and have an angled cut at the end to prevent water restriction. ? use ejector type holders to simplify electrode r emoval. ? keep the electrode and holder tapers clean to ensure good leak free conduction. ? dress electrodes frequently to insure good quality welds. ? use raw-hide or hard rubber hammers for alignment of electr odes. ? provide cooling water on the exit side top and bottom of seam welding applications. ? use properly designed knurling wheels to insure continuous dressing of the seam welding wheel. ? lock out the machine when performing any type of maintenance. ? never use unidentified electrodes or materials. ? avoid special, offset, or irregular electrodes when the job can be done with standard electrodes. ? do not use small electrodes on heavy gauge welding jobs or large electrodes on small gauge materials. ? do not forget to turn the water on full force before star ting to weld. ? never use water hoses that do not fit the water fitting properly. ? do not allow water connections to become leaky, clogged or broken. ? avoid holders with leaking or deformed tapers. ? nev er use holders that do not hav e adjustable water deflector tubes. ? never use pipe tape or similar product to stop a leak. ? do not let your electrode mushroom excessively. ? do not dress electrodes with a file. ? do not use a steel hammer to adjust any par t of a welding machine. ? do not permit seam welding wheels to run off the edge of the work piece. ? do not enter a work cell or reach into a welder without using your lockout.
tuffaloy products, inc. 1400 south batesville ? greer, south carolina 29650 tel: (800) 521-3722 ? (864) 879-0763 ? fax: (864) 877-2 212 visit our web site at: www.tuffaloy.com disclaimer and limited warranty tuffaloy products, inc. represents that the products described in this catalog will conform to the specifications contained in the catalog, but extends no other warranty with respect to the products. all such other warranties of any kind, expressed or implied, including the implied warranties of merchantability, fitness for a particular purpose and the warranty against infringement, are hereby disclaimed. if tuffaloy determines in its sole judgement that a product described in this catalog does not conform to the specifications, than tuffaloy will, upon return of the product to tuffaloy, freight prepaid, make a reasonable adjustment to the original purchase price or, at tuffaloys option, repair or replace the nonconforming product, f.o.b. tuffaloys facility. tuffaloy does not assume, and hereby disclaims, any and all liability for damages of any kind in connection with the products described in this catalog, including without limitation incidental and consequential damages and/or lost profits. although tuffaloy believes the information contained in this catalog to be accurate, it does not extend, and hereby disclaims, any warranty that such information is accurate and complete. tuffaloy reserves the right to change any specifications or other information in this catalog without notice. tuffaloy products, inc. C greer, south carolina, usa rwma member iso 9001:2000 certificate no.: qec15642

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