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Cause: Wrong Tips
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Definition
One or both of the electrode tips installed is not of the design
or material intended for the application.
Same as: wrong caps, improper electrodes, etc.
Description
Electrode tips are available in various shapes, sizes, and materials
to suit the design of the welding equipment, the geometry of the
parts being welded, or the material being welded. Substitution
of an inappropriate tip may adversely affect the available current
carrying area, the parallelism or alignment of the tip faces,
the amount of current required, or the shape of the resulting
weld.
Typical Welding Electrode Tips
Detection
Detectable evidence may include:
Significance
Quality, Workplace Issues, Cost, Downtime, Maintenance, Throughput
(cycle time; PPH), are all potentially affected by this condition.
Special considerations are noted below.
Quality:
- No-welds or undersized welds could result.
- Excessive indentation and expulsion may weaken the weld and
be visually unacceptable.
- Edge welding may occur.
Workplace Issues: Edge welding may result in heavy
expulsion leaving sharp edges.
Cost:
- Reduction in tip life may increase welding costs.
- Undersized welds may increase levels of rework
Downtime:
- Wrong tips may have to be changed immediately, necessitating
downtime.
- Excessive sticking may occur.
Throughput: Any downtime will reduce throughput.
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Information
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