Cause: Electrode Faces Not Parallel to Workpiece

Definition
Electrode faces not parallel to workpiece after tips have been closed.

Description
Line joining center points of contact areas is not perpendicular to workpiece.

Detection
A nonparallel electrode face condition may be detected through one or more of the following symptoms:

• Excessive indentation
• Expulsion/burn through
• Nonround weld
• Poor Class A appearance
• Sheet metal distortion
• Sticking/stuck tips
• Undersized weld
• Uneven indentation
• Visible nonparallelism of faces when the gun/fixture is closed

Significance
Quality, Workplace Issues, Cost, Downtime, Maintenance, Throughput (cycle time; PPH), are all potentially affected by this condition.

Subordinate Causes

• Incorrect electrode dressing
• Wrong shank
• Wrong tips

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