175-4251 [ETC]
standard straight tips;
| 型号： | 175-4251 |
| 厂家： | 
ETC |
| 描述： | standard straight tips |
| 文件： | 总54页 (文件大小：2157K) |
| 中文： | 中文翻译 | 下载： | 下载PDF数据表文档文件 |
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 ORDER BY TELEPHONE,
CALL TOLL FREE: 866.RES.WELD
(737.9353)
TO SHOP ONLINE, VISIT US AT:
www.rwelectrodes.com
table of contents
TUFFALOY
STANDARD ELECTRODES
RWMA Straight tips
2
5
8
11
12
13
14
14
TUFFCAP caps and shanks
Standard bent electrodes
Miscellaneous electrodes
Back up electrodes
Threaded electrodes
Swivel tips
Refractory metal-faced tips
WELDING TIP HOLDERS
Cylinder-mounted holders
Tip adapters
Multi-spot barrel and clamp
Straight holders
15
16
17
18
RESISTANCE
Offset holders and welder arms 22
Variable-offset holders
Paddle-type holders
Platen-mounted holders
Fast-follow-up holders
24
25
28
39
WELDING PRODUCTS
The little “TUFFALOY man” is now seventy years old. It was
in 1937 that Welding Sales & Engineering Company of
Detroit introduced a new line of resistance welding alloys
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 welding
accessories were added to the TUFFALOY product line. Today
this now-familiar name represents the most innovative and
respected resistance welding alloy and accessory company
in the field.
HIGH PRESSURE WELDING
Tips and holders
26
NUT AND STUD WELDING’
NUT AND STUD WELDING
Tips and holders
29
Auto nut feeder system components 31
GH series nutwelding heads
5 RW stud electrodes
32
33
Even 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’t find the answers in these pages, tell us what
you’re looking for. Let us work with you in finding solutions.
MULTIPLE WELDING
Dual-tip adapters
Dual-tip holders
Equa-Press holders
Triple-tip holders
34
35
36
38
RESISTANCE WELDING ALLOYS
Call your TUFFALOY distributor or TUFFALOY
Customer Services at 1-800-521-3722
or 864-879-0763. (Fax: 864-877-2212)
Welder arms
Bar stock
22
40
41
Refractory metals and forgings
ACCESSORIES
Visit our Internet site at:
http://www.tuffaloy.com
Shunts and jumpers
Miscellaneous
42
43
44
Weld force gauges
WELDING DATA
HELPFUL SUGGESTIONS
46
49
© Copyright Tuffaloy Products, 2007, 2009
1
TUFFALOY
standard straight tips
C
Straight tips from TUFFALOY are distinguished for
their 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.
B
B
A
A
E
E
TUFFALOY ensures conformity to all standard
dimensions. Before shipment, all tips must pass
inspection by gage for uniform length, taper, and
outline of point.
1/2
1/2
F
F
D
D
‘A’ POINTED NOSE
‘B’ DOME NOSE
RWMA CLASS 1
RWMA CLASS 2
RWMA CLASS 1
RWMA CLASS 2
A
C
D
E
F
B
Nose
Length
B
Descrip-
tion
Part
No.
Descrip-
tion
Part
No.
Descrip-
tion
Part
No.
Descrip-
tion
Part
No.
Overall WeIding Gauging Water Hole Water Hole
Length Face Dia.
Nose
Length
Dia.
Depth
Dia.
NO. 4 RW TAPER - 1/2” DIAMETER
1
3/16
3/16
3/16
3/16
3/16
3/16
3/16
3/16
3/16
3/16
3/16
3/16
3/16
.463
.463
.463
.463
.463
.463
.463
.463
.463
.463
.463
.463
.463
1/2
3/4
1
9/32
9/32
9/32
9/32
9/32
9/32
9/32
9/32
9/32
9/32
9/32
9/32
9/32
3/8
3/4
3/4
3/4
3/4
3/4
3/4
3/4
3/4
3/4
3/4
3/4
3/4
A-1404 131-1404 A-2404 132-2404
A-1405 131-1405 A-2405 132-2405
A-1406 131-1406 A-2406 132-2406
A-1407 131-1407 A-2407 132-2407
A-1408 131-1408 A-2408 132-2408
A-1409 131-1409 A-2409 132-2409
A-1410 131-1410 A-2410 132-2410
A-1411 131-1411 A-2411 132-2411
A-1412 131-1412 A-2412 132-2412
A-1413 131-1413 A-2413 132-2413
A-1414 131-1414 A-2414 132-2414
A-1415 131-1415 A-2415 132-2415
A-1416 131-1416 A-2416 132-2416
1/4
1/4
1/4
1/4
1/4
1/4
1/4
1/4
1/4
1/4
1/4
1/4
1/4
B-1404 133-1404 B-2404 134-2404
B-1405 133-1405 B-2405 134-2405
B-1406 133-1406 B-2406 134-2406
B-1407 133-1407 B-2407 134-2407
B-1408 133-1408 B-2408 134-2408
B-1409 133-1409 B-2409 134-2409
B-1410 133-1410 B-2410 134-2410
B-1411 133-1411 B-2411 134-2411
B-1412 133-1412 B-2412 134-2412
B-1413 133-1413 B-2413 134-2413
B-1414 133-1414 B-2414 134-2414
B-1415 133-1415 B-2415 134-2415
B-1416 133-1416 B-2416 134-2416
1-1/4
1-1/2
1-3/4
2
2-1/4
2-1/2
2-3/4
3
3-1/4
3-1/2
3-3/4
4
1-1/4
1-1/2
1-3/4
2
2-1/4
2-1/2
2-3/4
3
3-1/4
3-1/2
NO. 5 RW TAPER - 5/8” DIAMETER
1-1/4
1-1/2
1-3/4
2
2-1/4
2-1/2
2-3/4
3
3-1/4
3-1/2
3-3/4
4
1/4
1/4
1/4
1/4
1/4
1/4
1/4
1/4
1/4
1/4
1/4
1/4
.613
.613
.613
.613
.613
.613
.613
.613
.613
.613
.613
.613
3/4
3/4
1
3/8
3/8
3/8
3/8
3/8
3/8
3/8
3/8
3/8
3/8
3/8
3/8
1/2
7/8
7/8
7/8
7/8
7/8
7/8
7/8
7/8
7/8
7/8
7/8
A-1505 131-1505 A-2505 132-2505
A-1506 131-1506 A-2506 132-2506
A-1507 131-1507 A-2507 132-2507
A-1508 131-1508 A-2508 132-2508
A-1509 131-1509 A-2509 132-2509
A-1510 131-1510 A-2510 132-2510
A-1511 131-1511 A-2511 132-2511
A-1512 131-1512 A-2512 132-2512
A-1513 131-1513 A-2513 132-2513
A-1514 131-1514 A-2514 132-2514
A-1515 131-1515 A-2515 132-2515
A-1516 131-1516 A-2516 132-2516
3/8
3/8
3/8
3/8
3/8
3/8
3/8
3/8
3/8
3/8
3/8
3/8
B-1505 133-1505 B-2505 134-2505
B-1506 133-1506 B-2506 134-2506
B-1507 133-1507 B-2507 134-2507
B-1508 133-1508 B-2508 134-2508
B-1509 133-1509 B-2509 134-2509
B-1510 133-1510 B-2510 134-2510
B-1511 133-1511 B-2511 134-2511
B-1512 133-1512 B-2512 134-2512
B-1513 133-1513 B-2513 134-2513
B-1514 133-1514 B-2514 134-2514
B-1515 133-1515 B-2515 134-2515
B-1516 133-1516 B-2516 134-2516
1-1/4
1-1/2
1-3/4
2
2-1/4
2-1/2
2-3/4
3
3-1/4
NO. 6 RW TAPER - 3/4” DIAMETER
2
2-1/2
3
3-1/2
4
9/32
9/32
9/32
9/32
9/32
.731
.731
.731
.731
.731
1-1/4
1-3/4
2-1/4
2-3/4
3-1/4
7/16
7/16
7/16
7/16
7/16
1
1
1
1
1
A-1608 131-1608 A-2608 132-2608
A-1610 131-1610 A-2610 132-2610
A-1612 131-1612 A-2612 132-2612
A-1614 131-1614 A-2614 132-2614
A-1616 131-1616 A-2616 132-2616
3/8
3/8
3/8
3/8
3/8
B-1608 133-1608 B-2608 134-2608
B-1610 133-1610 B-2610 134-2610
B-1612 133-1612 B-2612 134-2612
B-1614 133-1614 B-2614 134-2614
B-1616 133-1616 B-2616 134-2616
NO. 7 RW TAPER - 7/8” DIAMETER
2
2-1/2
3
3-1/2
4
5/16
5/16
5/16
5/16
5/16
.844
.844
.844
.844
.844
1-1/4
1-3/4
2-1/4
2-3/4
3-1/2
1/2
1/2
1/2
1/2
1/2
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
3/8
3/8
3/8
3/8
3/8
B-1708 133-1708 B-2708 134-2708
B-1710 133-1710 B-2710 134-2710
B-1712 133-1712 B-2712 134-2712
B-1714 133-1714 B-2714 134-2714
B-1716 133-1716 B-2716 134-2716
2
standard straight tips
TUFFALOY
C
C
30˚
45˚ ON
TIPS 1-1/4
OR LESS IN
LENGTH
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
A
A
E
E
recommended uses of these alloys, see page 46.
To order Class 3 alloy tips, change description code
to indicate it: see “Key to Description”, page 4.
1/2
1/2
F
F
D
D
‘C’ FLAT NOSE
‘D’ OFFSET NOSE
RWMA CLASS 1
RWMA CLASS 2
RWMA CLASS 1
RWMA CLASS 2
A
D
E
F
C
C
Descrip-
tion
Part
No.
Descrip-
tion
Part
No.
Descrip-
tion
Part
No.
Descrip-
tion
Part
No.
Overall Gauging Water Hole Water Hole
Length
Welding
Face Dia.
Welding
Face Dia.
Dia.
Depth
Dia.
NO. 4 RW TAPER - 1/2” DIAMETER
1
.463
.463
.463
.463
.463
.463
.463
.463
.463
.463
.463
.463
.463
1/2
3/4
1
9/32
9/32
9/32
9/32
9/32
9/32
9/32
9/32
9/32
9/32
9/32
9/32
9/32
1/2
1/2
1/2
1/2
1/2
1/2
1/2
1/2
1/2
1/2
1/2
1/2
1/2
C-1404 135-1404 C-2404 136-2404
C-1405 135-1405 C-2405 136-2405
C-1406 135-1406 C-2406 136-2406
C-1407 135-1407 C-2407 136-2407
C-1408 135-1408 C-2408 136-2408
C-1409 135-1409 C-2409 136-2409
C-1410 135-1410 C-2410 136-2410
C-1411 135-1411 C-2411 136-2411
C-1412 135-1412 C-2412 136-2412
C-1413 135-1413 C-2413 136-2413
C-1414 135-1414 C-2414 136-2414
C-1415 135-1415 C-2415 136-2415
C-1416 135-1416 C-2416 136-2416
3/16
3/16
3/16
3/16
3/16
3/16
3/16
3/16
3/16
3/16
3/16
3/16
3/16
D-1404 137-1404 D-2404 138-2404
D-1405 137-1405 D-2405 138-2405
D-1406 137-1406 D-2406 138-2406
D-1407 137-1407 D-2407 138-2407
D-1408 137-1408 D-2408 138-2408
D-1409 137-1409 D-2409 138-2409
D-1410 137-1410 D-2410 138-2410
D-1411 137-1411 D-2411 138-2411
D-1412 137-1412 D-2412 138-2412
D-1413 137-1413 D-2413 138-2413
D-1414 137-1414 D-2414 138-2414
D-1415 137-1415 D-2415 138-2415
D-1416 137-1416 D-2416 138-2416
1-1/4
1-1/2
1-3/4
2
2-1/4
2-1/2
2-3/4
3
3-1/4
3-1/2
3-3/4
4
1-1/4
1-1/2
1-3/4
2
2-1/4
2-1/2
2-3/4
3
3-1/4
3-1/2
NO. 5 RW TAPER - 5/8” DIAMETER
1-1/4
1-1/2
1-3/4
2
2-1/4
2-1/2
2-3/4
3
3-1/4
3-1/2
3-3/4
4
.613
.613
.613
.613
.613
.613
.613
.613
.613
.613
.613
.613
3/4
3/4
1
3/8
3/8
3/8
3/8
3/8
3/8
3/8
3/8
3/8
3/8
3/8
3/8
5/8
5/8
5/8
5/8
5/8
5/8
5/8
5/8
5/8
5/8
5/8
5/8
C-1505 135-1505 C-2505 136-2505
C-1506 135-1506 C-2506 136-2506
C-1507 135-1507 C-2507 136-2507
C-1508 135-1508 C-2508 136-2508
C-1509 135-1509 C-2509 136-2509
C-1510 135-1510 C-2510 136-2510
C-1511 135-1511 C-2511 136-2511
C-1512 135-1512 C-2512 136-2512
C-1513 135-1513 C-2513 136-2513
C-1514 135-1514 C-2514 136-2514
C-1515 135-1515 C-2515 136-2515
C-1516 135-1516 C-2516 136-2516
1/4
1/4
1/4
1/4
1/4
1/4
1/4
1/4
1/4
1/4
1/4
1/4
D-1505 137-1505 D-2505 138-2505
D-1506 137-1506 D-2506 138-2506
D-1507 137-1507 D-2507 138-2507
D-1508 137-1508 D-2508 138-2508
D-1509 137-1509 D-2509 138-2509
D-1510 137-1510 D-2510 138-2510
D-1511 137-1511 D-2511 138-2511
D-1512 137-1512 D-2512 138-2512
D-1513 137-1513 D-2513 138-2513
D-1514 137-1514 D-2514 138-2514
D-1515 137-1515 D-2515 138-2515
D-1516 137-1516 D-2516 138-2516
1-1/4
1-1/2
1-3/4
2
2-1/4
2-1/2
2-3/4
3
3-1/4
NO. 6 RW TAPER - 3/4” DIAMETER
2
2-1/2
3
3-1/2
4
.731
.731
.731
.731
.731
1-1
7/16
7/16
7/16
7/16
7/16
3/4
3/4
3/4
3/4
3/4
C-1608 135-1608 C-2608 136-2608
C-1610 135-1610 C-2610 136-2610
C-1612 135-1612 C-2612 136-2612
C-1614 135-1614 C-2614 136-2614
C-1616 135-1616 C-2616 136-2616
9/32
9/32
9/32
9/32
9/32
D-1608 137-1608 D-2608 138-2608
D-1610 137-1610 D-2610 138-2610
D-1612 137-1612 D-2612 138-2612
C-1614 137-1614 D-2614 138-2614
D-1616 137-1616 D-2616 138-2616
1-3/4
2-1/4
2-3/4
3-1/4
NO. 7 RW TAPER - 7/8” DIAMETER
2
2-1/2
3
3-1/2
4
.844
.844
.844
.844
.844
1-1/4
1-3/4
2-1/4
2-3/4
3-1/2
1/2
1/2
1/2
1/2
1/2
7/8
7/8
7/8
7/8
7/8
C-1708 135-1708 C-2708 136-2708
C-1710 135-1710 C-2710 136-2710
C-1712 135-1712 C-2712 136-2712
C-1714 135-1714 C-2714 136-2714
C-1716 135-1716 C-2716 136-2716
5/16
5/16
5/16
5/16
5/16
D-1708 137-1708 D-2708 138-2708
D-1710 137-1710 D-2710 138-2710
D-1712 137-1712 D-2712 138-2712
D-1714 137-1714 D-2714 138-2714
D-1716 137-1716 D-2716 138-2716
3
TUFFALOY
standard straight tips
C
TAPER ENGAGEMENT
TIP SIZE
LENGTH
1/2-in.
3/4-in.
7/8-in.
1-1/8-in.
R
45°
4 RW
5 RW
6 RW
7 RW
A
A
KEY TO DESCRIPTION
E
E
Nose Designation
RWMA
Alloy Class
1/2
1/2
E-2-5-10
RW Taper No.
Length, in Number of 1/4-in. increments
F
D
F
D
‘E’ TRUNCATED CONE
‘F’ RADIUS FACED
RWMA CLASS 1
RWMA CLASS 2
RWMA CLASS 1
RWMA CLASS 2
A
D
E
F
C
R
Descrip-
tion
Part
No.
Descrip-
tion
Part
No.
Descrip-
tion
Part
No.
Descrip-
tion
Part
No.
Overall Gauging Water Hole Water Hole
Length
Welding
Face Dia.
Nose
Radius
Dia.
Depth
Dia.
NO. 4 RW TAPER - 1/2” DIAMETER
1
.463
.463
.463
.463
.463
.463
.463
.463
.463
.463
.463
.463
.463
1/2
3/4
1
9/32
9/32
9/32
9/32
9/32
9/32
9/32
9/32
9/32
9/32
9/32
9/32
9/32
3/16
3/16
3/16
3/16
3/16
3/16
3/16
3/16
3/16
3/16
3/16
3/16
3/16
E-1404 140-1404 E-2404 140-2404
E-1405 140-1405 E-2405 140-2405
E-1406 140-1406 E-2406 140-2406
E-1407 140-1407 E-2407 140-2407
E-1408 140-1408 E-2408 140-2408
E-1409 140-1409 E-2409 140-2409
E-1410 140-1410 E-2410 140-2410
E-1411 140-1411 E-2411 140-2411
E-1412 140-1412 E-2412 140-2412
E-1413 140-1413 E-2413 140-2413
E-1414 140-1414 E-2414 140-2414
E-1415 140-1415 E-2415 140-2415
E-1416 140-1416 E-2416 140-2416
2
2
2
2
2
2
2
2
2
2
2
2
2
F-1404 141-1404 F-2404 141-2404
F-1405 141-1405 F-2405 141-2405
F-1406 141-1406 F-2406 141-2406
F-1407 141-1407 F-2407 141-2407
F-1408 141-1408 F-2408 141-2408
F-1409 141-1409 F-2409 141-2409
F-1410 141-1410 F-2410 141-2410
F-1411 141-1411 F-2411 141-2411
F-1412 141-1412 F-2412 141-2412
F-1413 141-1413 F-2413 141-2413
F-1414 141-1414 F-2414 141-2414
F-1415 141-1415 F-2415 141-2415
F-1416 141-1416 F-2416 141-2416
1-1/4
1-1/2
1-3/4
2
2-1/4
2-1/2
2-3/4
3
3-1/4
3-1/2
3-3/4
4
1-1/4
1-1/2
1-3/4
2
2-1/4
2-1/2
2-3/4
3
3-1/4
3-1/2
NO. 5 RW TAPER - 5/8” DIAMETER
1-1/4
1-1/2
1-3/4
2
2-1/4
2-1/2
2-3/4
3
3-1/4
3-1/2
3-3/4
4
.613
.613
.613
.613
.613
.613
.613
.613
.613
.613
.613
.613
3/4
3/4
1
3/8
3/8
3/8
3/8
3/8
3/8
3/8
3/8
3/8
3/8
3/8
3/8
1/4
1/4
1/4
1/4
1/4
1/4
1/4
1/4
1/4
1/4
1/4
1/4
E-1505 140-1505 E-2505 140-2505
E-1506 140-1506 E-2506 140-2506
E-1507 140-1507 E-2507 140-2507
E-1508 140-1508 E-2508 140-2508
E-1509 140-1509 E-2509 140-2509
E-1510 140-1510 E-2510 140-2510
E-1511 140-1511 E-2511 140-2511
E-1512 140-1512 E-2512 140-2512
E-1513 140-1513 E-2513 140-2513
E-1514 140-1514 E-2514 140-2514
E-1515 140-1515 E-2515 140-2515
E-1516 140-1516 E-2516 140-2516
2
2
2
2
2
2
2
2
2
2
2
2
F-1515 141-1505 F-2505 141-2505
F-1506 141-1506 F-2506 141-2506
F-1507 141-1507 F-2507 141-2507
F-1508 141-1508 F-2508 141-2508
F-1509 141-1509 F-2509 141-2509
F-1510 141-1510 F-2510 141-2510
F-1511 141-1511 F-2511 141-2511
F-1512 141-1512 F-2512 141-2512
F-1513 141-1513 F-2513 141-2513
F-1514 141-1514 F-2514 141-2514
F-1515 141-1515 F-2515 141-2515
F-1516 141-1516 F-2516 141-2516
1-1/4
1-1/2
1-3/4
2
2-1/4
2-1/2
2-3/4
3
3-1/4
NO. 6 RW TAPER - 3/4” DIAMETER
2
2-1/2
3
3-1/2
4
.731
.731
.731
.731
.731
1-1/4
1-3 /4
2-1/4
2-3/4
3-1/4
7/16
7/16
7/16
7/16
7/16
9/32
9/32
9/32
9/32
9/32
E-1608 140-1618 E-2608 140-2608
E 1610 140-1610 E-2610 140-2610
E-1612 140-1612 E-2612 140-2612
E-1614 140-1614 E-2614 140-2614
E-1616 140-1616 E-2616 140-2616
4
4
4
4
4
F-1608 141-1608 F-2608 141-2608
F-1610 141-1610 F-2610 141-2610
F-1612 141-1612 F-2612 141-2612
F-1614 141-1614 F-2614 141-2614
F-1616 141-1616 F-2616 141-2616
NO. 7 RW TAPER - 7/8” DIAMETER
2
2-1/2
3
3-1/2
4
.844
.844
.844
.844
.844
1-1/4
1-3/4
2-1/4
2-3/4
3-1/2
1/2
1/2
1/2
1/2
1/2
5/16
5/16
5/16
5/16
5/16
E-1708 140-1708 E-2708 140-2708
E-1710 140-1710 E-2710 140-2710
E-1712 140-1712 E-2712 140-2712
E-1714 140-1714 E-2714 140-2714
E-1716 140-1716 E-2716 140-2716
6
6
6
6
6
F-1708 141-1708 F 2708 141-2708
F-1710 141-1710 F-2710 141-2710
F-1712 141-1712 F-2712 141-2712
F-1714 141-1714 F-2714 141-2714
F-1716 141-1716 F-2716 141-2716
4
caps and shanks
TUFFALOY
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
inventory can be kept small because all nose designs
will fit the same size shank.
Female Cap Type
Electrode Assembly
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.
Male Cap Type
Electrode Assembly
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 galvanized or tin-plate.
Size 5 RW straight
and offset style shanks
holding male type caps
with swivel heads.
These caps are cataloged
on pages 6 & 7.
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.
NEW! SUPER NOSE DESIGN CAPS
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 TUFFALOY’s new “Z” material, 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.
U.S. Patent Number 5,155,320
Other patents pending
5
TUFFALOY
caps and shanks
STRAIGHT SHANKS FOR MALE CAPS (CLASS 2*)
MALE CAPS
Taper of
Adapter
Shank
Shank Assembled Descip-
Part
No.
Alloy
Class
Descrip-
tion
Part
No.
POINTED TIPS ‘A’
Length
Length
tion
1-1/4
1-1/2
1-3/4
2
2-1/4
2-1/2
2-3/4
3
2
TG-2405 161-2405
TG-2406 161-2406
TG-2407 161-2407
TG-2408 161-2408
TG-2409 161-2409
TG-2410 161-2410
TG-2411 161-2411
TG-2412 161-2412
TG-2413 161-2413
1
2
3
4RW TA-14 111-0014
4RW TA-24 112-0024
4RW TA-34 122-1034
2-1/4
2-1/2
2-3/4
3
3-1/4
3-1/2
3-3/4
4
SHANKS 4 RW TAPER
1
5RW TA-15 111-0015
1&2 5RW TA-25Z 126-0025
2
3
5RW TA-25 112-0025
5RW TA-35 122-1035
3-1/4
1
2
6RW TA-16 111-0016
6RW TA-26 112-0026
1-1/4
1-1/2
1-3/4
2
2-1/4
2-1/2
2-3/4
3
2
TG-2505 161-2505
TG-2506 161-2506
TG-2507 161-2507
TG-2508 161-2508
TG-2509 161-2509
TG-2510 161-2510
TG-2511 161-2511
TG-2512 161-2512
TG-2513 161-2513
2-1/4
2-1/2
2-3/4
3
3-1/4
3-1/2
3-3/4
4
SHANKS 5 RW TAPER
SHANKS 6 RW TAPER
1
2
7RW TA-17 111-0017
7RW TA-27 112-0027
3-1/4
Z
4RW TS-24Z 127-0024
Other sizes available
Z
5RW TS-25Z 127-0025
1-1/2
2
2-1/2
3
2-1/2
3
3-1/2
4
TG-2606 161-2606
TG-2608 161-2608
TG-2610 161-2610
TG-2612 161-2612
DOME TIPS ‘B’
1
2
4RW TB-14 113-0014
4RW TB-24 114-0024
1
2
5RW TB-15 113-0015
5RW TB-25 114-0025
SHANKS 7 RW TAPER
1-1/2
2
2-1/2
3
2-1/2
3
3-1/2
4
TG-2706 161-2706
TG-2708 161-2708
TG-2710 161-2710
TG-2712 161-2712
1
2
6RW TB-16 113-0016
6RW TB-26 114-0026
1
2
7RW TB-17 113-0017
7RW TB-27 114-0027
‘E’ NOSE
‘F’ NOSE
4 AND 5 CAP
4 AND 5 CAP
FLAT TIPS ‘C’
1
2
3
4RW TC-14 115-0014
4RW TC-24 116-0024
4RW TC-34 122-3034
BENT SHANKS FOR MALE CAPS (CLASS 2*)
1
2
3
5RW TC-15 115-0015
5RW TC-25 116-0025
5RW TC-35 122-3035
Shank Off-
Length set
Descip-
tion
Part
No.
Length
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
SHANKS 4 RW TAPER
1
2
6RW TC-16 115-0016
6RW TC-26 116-0026
2-1/2
3
1
3-1/4 TG-2410-16 162-2430
1/2 3-3/4 TG-2412-8 162-2450
1-1/4 3-3/4 TG-2412-20 162-2460
3
3-1/4
3-1/4 1-1/4
1
4
4
TG-2413-16 162-2470
TG-2413-20 162-2480
1
2
7RW TC-17 115-0017
7RW TC-27 116-0027
OFFSET TIPS ‘D’
1
2
3
4RW TD-14 117-0014
4RW TD-24 118-0024
4RW TD-34 122-4034
2-1/4 1/4
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
3
TG-2509-4 162-2505
1
2
3
5RW TD-15 117-0015
5RW TD-25 118-0025
5RW TD-35 122-4035
SHANKS 5 RW TAPER
2-1/2
3
3
1
3-1/4 TG-2510-16 162-2530
1/2 3-3/4 TG-2512-8 162-2550
1-1/4 3-3/4 TG-2512-20 162-2560
1
2
6RW TD-16 117-0016
6RW TD-26 118-0026
3-1/4
1
4
4
TG-2513-16 162-2570
TG-2513-20 162-2580
3-1/4 1-1/4
1
2
7RW TD-17 117-0017
7RW TD-27 118-0027
* Class 3 Available
6
caps and shanks
TUFFALOY
STRAIGHT SHANKS FOR FEMALE CAPS (CLASS 2*)
FEMALE CAPS
SHANKS 4 RW TAPER
Taper of
Adapter
Shank
Shank Assembled Descrip-
Part
No.
Alloy
Class
Descrip-
tion
Part
No.
Length
Length
tion
POINTED TIPS ‘A’
1-1/2
1-3/4
2
2-1/4
2-1/2
2-3/4
3
2
TP-2406 163-2406
TP-2407 163-2407
TP-2408 163-2408
TP-2409 163-2409
TP-2410 163-2410
TP-2411 163-2411
TP-2412 163-2412
TP-2413 163-2413
TP-2414 163-2414
2
2
4RW TP-24A 125-0241
2-1/4
2-1/2
2-3/4
3
3-1/4
3-1/2
3-3/4
4
.840
5RW TP-25A 125-0251
3-1/4
3-1/2
SHANKS 5 RW TAPER
1-1/2
1-3/4
2
2-1/4
2-1/2
2-3/4
3
2
TP-2506 163-2506
TP-2507 163-2507
TP-2508 163-2508
TP-2509 163-2509
TP-2510 163-2510
TP-2511 163-2511
TP-2512 163-2512
TP-2513 163-2513
TP-2514 163-2514
2
Z
6RW TP-26A 125-0261
4RW TP-24SZ 127-0241
2-1/4
2-1/2
2-3/4
3
3-1/4
3-1/2
3-3/4
4
Other sizes available
Z
5RW TP-25SZ 127-0251
3-1/4
3-1/2
DOME TIPS ‘B’
SHANKS 6 RW TAPER
2
4RW TP-24B 125-0242
5RW TP-25B 125-0252
1-1/2
2
2-1/2
3
2
TP-2606 163-2606
TP-2608 163-2608
TP-2610 163-2610
TP-2612 163-2612
.840
2-1/2
3
3-1/2
2
2
‘E’ NOSE
4 AND 5 CAP
‘F’ NOSE
4 AND 5 CAP
6RW TP-26B 125-0262
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.
FLAT TIPS ‘C’
2
2
4RW TP-24C 125-0243
5RW TP-25C 125-0253
.840
BENT SHANKS FOR FEMALE CAPS (CLASS 2*)
Shank Off-
Length set
Descrip-
tion
Item
No.
Length
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
SHANKS 4 RW TAPER
2-3/4
1
3-1/4 TP-2411-16 164-2447
2
6RW TP-26C 125-0263
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
OFFSET TIPS ‘D’
2
2
4RW TP-24D 125-0244
5RW TP-25D 125-0254
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
SHANKS 5 RW TAPER
2-3/4
3-1/4 1/2 3-3/4 TP-2513-08 164-2565
3-1/2 TP-2513-16 164-2570
3-1/4 1-1/4 3-3/4 TP-2513-20 164-2580
1
3-1/4 TP-2511-16 164-2547
1
4
2
6RW TP-26D 125-0264
* Class 3 Available
7
TUFFALOY
bent tips
DOUBLE-BEND, WITH STANDARD NOSE DESIGNS
These 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 “Key to Description”,
using a ‘B’ for Dome nose, ‘C’ for flat nose, ‘E’ for truncated cone, and ‘F’ for radius nose.
DOUBLE-BENT, ADDITIONAL NOSE DESIGNS
‘A’ POINTED NOSE
‘B’ DOME NOSE
‘C’ FLAT NOSE
‘D’ OFFSET NOSE
CLASS I
FA Pointed Nose
CLASS 2
FA Pointed Nose
KEY TO DESCRIPTION
FD Offset Nose
FD Offset Nose
Taper
No.
Offset
Length
Descrip-
tion
Item
No.
Descrip-
tion
Item
No.
Descrip-
tion
Item
No.
Descrip-
tion
Item
No.
FX-YZLD-O
1-1/2
2-3/16
2-1/4
2-1/4
2-3/8
2-3/8
2-3/8
2-1/2
2-1/2
2-5/8
2-3/4
2-3/4
2-3/4
2-7/8
2-7/8
3
7/16
1
FA-2317-8
167-0060
FD-2423-16
167-2080
1/2
3/4
3/8
3/4
1-1/4
1/2
1
3/4
1/2
1
1-1/4
3/4
1-1/4
1
1-1/4
1
FA-1424-8
FA-1426-6
FA-1426-20
165-0100
165-0160
165-0200
FA-2424-8
FA-2424-12
FA-2426-6
FA-2426-12
FA-2426-20
FA-2428-8
FA-2428-16
FA-24210-12 167-0320
FA-24212-8 167-0360
FA-24212-16 167-0400
FA-24212-20 167-0420
FA-24214-12 167-0430
FA-24214-20 167-0460
167-0100
167-0120
167-0160
167-0180
167-0200
167-0240
167-0280
Example:
FB-1438-16-T
FD-1426-20
FD-1428-16
165-2200
165-2280
FD-2426-20
167-2200
F = Cold-Formed,
4
RW
FA-1428-16
FA-14210-12
FA-14212-8
165-0280
165-0320
165-0360
FD-2428-16
FD-24210-12
FD-24212-8
167-2280
167-2320
167-2360
Double-Bend Tips
X = Nose Type
A
B
C
D
FA-14214-20
FA-1430-16
165-0460
165-0520
FA-2430-16
FA-2436-20
FA-2438-16
167-0520
167-0580
167-0620
3-3/8
3-1/2
Y = RWMA Alloy Class
1 = Class 1
2-1/4
2-1/4
2-3/8
2-3/8
2-7/16
2-1/2
2-1/2
2-3/4
2-3/4
2-3/4
2-7/8
2-7/8
3
1/2
1-1/4
3/8
3/4
1-5/16
1/2
1
1/2
3/4
1
FD-2524-8
FD-2524-20
FD-2526-6
FD-2526-12
167-3100
167-3140
167-3160
167-3180
FD-1524-20
FD-1526-12
165-3140
165-3180
2 = Class 2
FA-1526-6
165-1160
FA-2526-6
FA-2526-12
167-1160
167-1180
Z = RW Taper Number
4 =4RW
FA-1528-8
FA-15212-8
FA-15212-16
165-1240
165-1360
165-1400
FA-2528-8
FA-2528-16
FA-25212-8
FA-25212-12 167-1380
FA-25212-16 167-1400
FA-25214-16 167-1440
FA-25214-20 167-1460
FA-2530-8
FA-2530-12
FA-2530-28
FA-2534-16
167-1240
167-1280
167-1360
5 = 5RW
FD-15212-8
165-3360
165-3400
FD-25212-8
167-3360
167-3400
L = Length in inches
Refer to table
FD-15212-16
FD-25212-16
5
RW
for availability
1
1-1/4
1/2
3/4
1
FA-15214-20
FA-1530-8
165-1460
165-1480
D = Additional Length
167-1480
167-1500
167-1540
167-1560
FD-2530-8
167-3480
167-3520
in 16ths
3
3
FD-2530-16
O = Offset in 16ths
Refer to table
3-1/4
3-3/8
3-3/8
3-1/2
3-1/2
1
FA-1534-16
165-1560
3/8
1-1/4
1/2
1
FD-1536-6
FD-1536-20
165-3570
165-3580
FA-1536-20
FA-1538-8
165-1580
165-1600
FA-2536-20
FA-2538-8
FA-2538-16
167-1580
167-1600
167-1620
FD-2536-20
FD-2538-16
167-3580
167-3620
for availability
T = With water tubes
8
bent tips
TUFFALOY
‘A’ POINTED NOSE
FA-1426-6 FA-2426-6
FA-1526-6 FA-2526-6
FA-1426-20 FA-2426-20
FA-2428-8
FA-1528-8 FA-2528-8
FA-1428-16 FA-2428-16
FA-2528-16
FA-14212-8 FA-24212-8
FA-15212-8 FA-25212-8
FA-14214-20 FA-24214-20
FA-15214-20 FA-25214-20
FA-1430-16 FA-2430-16
FA-2436-20
FA-1538-8 FA-2538-8
FA-15212-16 FA-25212-16
FA-1536-20 FA-2436-20
‘D’ OFFSET NOSE
FD-1426-20 FD-2426-20
FD-1428-16 FD-2428-16
FD-1524-20 FD-2524-20
FD-2526-6
FD-1526-12 FD-2526-12
FD-24210-12
FD-24212-8
FD-15212-8 FD-25212-8
FD-15212-16 FD-25212-16
FD-1536-20 FD-2536-20
FD-2538-16
9
TUFFALOY
bent tips
SINGLE-BEND 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
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
configurations are available on special order. These
are of Class 2 alloy; Class I alloy can also be ordered.
SE-4268
Part No. 170-4268
SE-4269
Part No. 170-4269
MISCELLANEOUS TIPS
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
alloy can also be ordered.
SE-4270
Part No. 170-4270
SE-4271
Part No. 170-4271
SE-4272
Part No. 170-4272
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
10
miscellaneous tips
TUFFALOY
These standard bent tips are in addition to those shown on page 9.
They are of class 2 alloy; Other alloys can also be ordered.
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-4288
Part No. 170-4288
SE-4282
Part No. 170-4282
SE-4283
Part No. 170-4283
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
11
TUFFALOY
miscellaneous tips
SE-4535
Part No. 186-0520
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
These straight tips have welding
faces angled 30’.
N-15 thru N-28
Alloy
Class
Taper
No.
Length
‘L’
Descrip-
tion
Part
No.
2
2
2
4RW
4RW
4RW
2
3
4
H-2408-30 145-2408
H-2412-30 145-2412
H-2416-30 145-2416
Alloy
Class
Taper Length Descrip-
Part
No.
No.
‘N’
tion
2
2
2
2
4RW
4RW
5RW
5RW
3/8
3/4
3/8
3/4
N-15
N-16
N-27
N-28
186-0015
186-0016
186-0027
186-0028
2
2
2
5RW
5RW
5RW
2
3
4
H-2508-30 145-2508
H-2512-30 145-2512
H-2516-30 145-2516
BACK UP ELECTRODES
RECTANGULAR FACE
Alloy
Class
Taper
No.
Face
‘F’
Descrip-
tion
Part
No.
2
2
2
2
5RW
4RW
4RW
5RW
1
1/2
1
220
221
223
224
186-0220
186-0221
186-0223
186-0224
1
2
2
2
5RW
5RW
4RW
1
2
2
225
226
227
186-0225
186-0226
186-0227
2
2
5RW
4RW
1-1/2
1-1/2
228
229
186-0228
186-0229
ROUND FACE
Alloy
Class
Taper
No.
Face
‘F’
Descrip-
tion
Part
No.
220
221 thru 224
225
226 thru 229
2
1
2
1
4RW
4RW
5RW
5RW
7/8
7/8
7/8
7/8
301
302
303
304
186-0301
186-0302
186-0303
186-0304
These tips are all machined from bar stock.
Special designs can be made to order.
2
1
2
4RW
4RW
5RW
7/8
7/8
7/8
305
306
307
186-0305
186-0306
186-0307
1
2
1
5RW
4RW
4RW
7/8
1
1
308
309
310
186-0308
186-0309
186-0310
*311, 313 and
316 available
with Copper
Tungsten face.
See pg. 32
*
2
1
2
2
2
5RW
5RW
5RW
5RW
5RW
1
1
311
312
313
315
316
186-0311
186-0312
186-0313
186-0315
186-0316
5/8
*
*
1-1/4
1-1/2
1
Additional Back Up Electrodes with
Copper Tungsten Facings – See Page 32
301 thru 304
305 thru 315
316
12
threaded tips
TUFFALOY
Tuffaloy threaded
electrodes are
Class 2 alloy.
Other materials
are available.
FLAT ELECTRODES
A
B
Tip
C
Male
Overall
Description
Part No.
Length Dia. (Hex)
Thread
2
1
1
1
5/8-11
5/8-18
3/4-11
3/4-10
5100-11-C
5100-18-C
5100-10-C
5125-10-C
187-5100-11
187-5100-18
187-5100-10
187-5125-10
1-1/4
TRUNCATED ELECTRODES
A
B
Tip
C
Overall
Length Dia. (Hex)
Male
Thread
Description
Part No.
2
1
1
1
5/8-11
5/8-18
3/4-10
3/4-10
5100-11-E
5100-18-E
5100-10-E
5125-10-E
188-5100-11
188-5100-18
188-5100-10
188-5125-10
1-1/4
“C” NOSE ELECTRODES
A
B
Tip
C
Male
Overall
Description
Part No.
Length Dia. (Hex)
Thread
3/4
3/4
5/8
5/8
7/16-14
3/8-16
5062-14-C
5062-16-C
187-5062-14
187-5062-16
“E” NOSE ELECTRODES
A
B
Tip
C
Male
Overall
Description
Part No.
Length Dia. (Hex)
Thread
‘
3/4 5/8
7/16-14
5062-14-E
188-5062-14
13
TUFFALOY
swivel tips
Swivel tips have ball-jointed
swivel heads to compensate
for minor misalignment, and
to eliminate marking of the
work surface. They are all
machined from Class 2 alloy
bar 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
F
2
S-Series
OS-Series
OS-Series
OSH-Series
OSH-Series
S-Series*
(Tuffcap Design)
SS-Series
SS-Series
S-Series
Descrip-
Face
Dia.
‘F’
Taper
Part
No.
Descrip.
Part
No.
Descrip-
Part
No.
Descrip-
tion
Part
No.
No.
tion
tion
tion
better positioning.
Class 1 and class 3
heads are also available.
7/8
1
S-248
S-249
S-250
182-0248
182-0249
182-0250
5-CT*
1-1/4
7/8
1
1-1/4
S-348
S-350
S-351
182-0348
182-0350
182-0351
OS-348
OS-350
OS-351
182-1348
182-1350
182-1351
4RW
Note: Standard swivel
tilt is approximately
18’, a 25’ swivel is
available on request.
Add suffix “HS” to
above part number.
7/8
1
1-1/4
1-1/2
2
S-349
S-353
S-354
182-0349
182-0353
182-0354
OS-349
OS-353
OS-354
182-1349
182-1353
182-1354
OSH-353
OSH-354
OSH-356
OSH-358
182-2353
182-2354
182-2356
182-2358
SS-353
SS-354
182-3353
182-3354
5RW
7RW
2-1/2
3360
182-3360
*Will fit Tuffcap adapter shanks having No. 5 RW tapers, as shown on page 6.
TUFFALOY
refractory metal-faced tips
Dimensions
Nose
Type
Taper
No.
Facing Alloy
Class
Descrip-
tion
Part
No.
A
B
4RW
4RW
5RW
5RW
5RW
14
13
11
14
13
3/16
3/16
1/4
1/4
1/4
3/8
3/8
3/8
3/8
3/8
A-2408-100M
A-2408-100W
A-2508-10W
A-2508-100M
A-2508-100W
185-0120
185-0130
185-0150
185-0160
185-0170
Pointed
Dome
Flat
4RW
5RW
5RW
11
11
13
1/2
5/8
5/8
1/4
1/4
1/4
B-2408-10W
B-2508-10W
B-2508-100W
185-1110
185-1120
185-1170
POINTED NOSE ‘A’
4RW
4RW
4RW
5RW
5RW
5RW
11
14
13
11
14
13
1/2
1/2
1/2
5/8
5/8
5/8
1/4
1/4
1/4
1/4
1/4
1/4
C-2408-10W
C-2408-100M
C-2408-100W
C-2508-10W
C-2508-100M
C-2508-100W
185-1210
185-1220
185-1230
185-1250
185-1260
185-1270
The TUFFALOY copper-tungsten, tungsten and molybdenum-faced tips
listed here withstand greater heat and pressure, at the expense of
some conductivity. Besides being used for spot welding high resistance
base metals, they are useful in achieving “heat balance” when 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.
DOME NOSE ‘B’
FLAT NOSE ‘C’
14
cylinder-mounted holders
TUFFALOY
These standard-tip holders are mounted directly to
air 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.
OFFSET HOLDERS
4 & 5 RW
6 & 7RW
Part No.
3/4” Pipe
Offset
Width
(inches) (inches)
Part No.
1/2” Pipe
1.0
2.5
2.5
194-1588
194-1587
194-1586
194-1585
194-1584
194-1583
194-1582
194-1581
194-1598
194-1596
194-1594
0.88
0.75
0.62
0.50
0.38
0.25
0.12
2.31
2.18
2.06
1.94
1.81
1.68
ORDER CLAMP SEPARATELY
For 7/8 straight-thread adapters use suffix
“7/8-14 N.F.” Example: 194-1588-7/8-14 NF.
STATIONARY WATER TUBES
FOR 4 & 5 RW TIPS
FOR 6 OR 7 RW TIPS
HOLDER
CLAMP 101-2:
PART NO. 194-2040
STATIONARY WATER TUBES
FOR 4RW USE
FOR 5RW, 6RW
OR 7RW USE
1/4 NTP HOSE
CONNECTION 8241:
PART NO. 195-8241
Descrip-
Part
No.
Descrip-
Part
No.
Length
tion
tion
3/4
1
1-1/4
1-1/2
1-3/4
2
2-1/2
3
3-1/2
4
301-.7
301-1.0
301-1.2
301-1.5
301-1.7
301-2.0
301-2.5
301-3.0
301-3.5
301-4.0
301-4.5
194-3107
194-3110
194-3112
194-3115
194-3117
194-3120
194-3125
194-3130
194-3135
194-3140
194-3145
312-.7
312-1.0
312-1.2
312-1.5
312-1.7
312.2.0
312-2.5
312-3.0
312-3.5
312-4.0
312-4.5
194-3207
194-3210
194-3212
194-3215
194-3217
194-3220
194-3225
194-3230
194-3235
194-3240
194-3245
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 approximately flush with adapter face.
4-1/2
15
TUFFALOY
tip adapters
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.
A
B
C
Body
Size
D
E
Pipe Thread
or Taper
Taper
Socket
Body
Length
Over-All
Length
Description
Part Number
1/4
7/8
1
1-1/4
1-1/2
1-3/4
2
2-1/4
2-1/2
2-3/4
3
AD-124-.8
AD-124-1.0
AD-124-1.2
AD-124-1.5
AD-124-1.7
AD-124-2.0
AD-124-2.2*
AD-124-2.5
AD-124-2.7*
AD-124-3.0
AD-124-3.2*
AD-124-3.5
AD-124-3.7*
AD-124-4.0
AD-124-5.0*
190-1408
190-1410
190-1412
190-1415
190-1417
190-1420
3/8
5/8
7/8
AD-124-.8, AD-125-.8,
AD-584-.8, AD-585-.8,
1-1/8
1-3/8
1-5/8
1-7/8
2-1/8
2-3/8
2-5/8
2-7/8
3-1/8
3-3/8
4-3/8
1/2-14
NPT
4RW
1” Hex
190-1425
190-1430
190-1435
190-1440
3-1/4
3-1/2
3-3/4
4
AD-124-1.0, AD-124-4.0,
AD-125-1.0, AD-125-4.0,
AD-345-1.0, AD-347-4.0,
5
1/4
3/8
7/8
1
1-1/4
1-1/2
1-5/8
1-3/4
2
2-1/4
2-1 /2
2-3/4
3
AD-125-.8
AD-125-1.0
AD-125-1.2
AD-125-15
AD-125-1.6*
AD-125-1.7
AD-125-2.0
AD-125-2.2*
AD-125-2.5
AD-125-2.7*
AD-125-3.0
AD-125-3.2*
AD-125-3.5
AD-125-3.7*
AD-125-4.0
AD-125-4.5
190-1508
190-1510
190-1512
190-1515
5/8
7/8
1
1-1/8
1-3/8
1-5/8
1-7/8
2-1/8
2-3/8
2-5/8
2-7/8
3-1/8
3-3/8
3-7/8
190-1517
190-1520
1/2-14
NPT
5RW
1” Hex
190-1525
190-1530
190-1535
AD-45-2, AD-45-4,
3-1/4
3-1/2
3-3/4
4
190-1540
190-1545
190-2408
4-1/2
AD-54-1, AD-75-2,
1/4
3/8
7/8
1
1-1/2
2
AD-584-.8
AD-584-1.0
AD-584-1.5*
AD-584-2.0*
5/8-14
NPT
4RW
5RW
1” Hex
1” Hex
7/8
1-3/8
1/4
3/8
7/8
1
AD-585-.8
AD-585-1.0*
AD-585-1.2
AD-585-1.5
AD-585-1.7
AD-585-2.0*
AD-585-2.5*
AD-585-3.0*
AD-585-4.0*
190-2508
190-2510
190-2512
190-2515
190-2517
5/8
1-1/4
1-1/2
1-3/4
2
5/8-14
NPT
7/8
1-1/8
1-3/8
1-7/8
2-3/8
3-3/8
2-1/2
3
4
AD-55-90, for 5 RW Tip,
Part No. 190-9559
3/16
7/16
1-1/8
1-3/8
1-1/2
1-3/4
2
AD-345-1.1*
AD-345-1.3*
AD-345-1.5
AD-345-1.7
AD-345-2.0
AD-345-2.5
AD-345-3.0
AD-345-3.5
AD-345-4.0
AD-345-5.0
AD-54-90, for 4 RW Tip,
Part No. 190-9549
AD-55-30, for 5 RW Tip,
Part No. 190-9553
9/16
190-3515
190-3517
190-3520
190-3525
190-3530
190-3535
190-3540
190-3550
13/16
1-1/16
1-9/16
2-1/16
2-9/16
3-1/16
4-1/16
3/4-14
NPT
5RW
6RW
7RW
1.25 Hex
1.25 Hex
1.25 Hex
2-1/2
3
STRAIGHT THREADED ADAPTERS FOR
MULTI-SPOT BARREL AND CLAMP
3-1/2
4
5
5/16
7/16
1-1/4
1-3/8
1-1/2
2
AD-346-1.2*
AD-346-1.3
AD-346-1.5
AD-346-2.0
AD-346-2.5
AD-346-2.7*
AD-346-3.0
AD-346-3.5
AD-346-4.0
AD-346-4.5
AD-346-5.0
AD-347-1.5
AD-347-2.0
AD-347-2.5
AD-347-3.0
AD-347-3.5
AD-347-4.0
AD-347-4.5
AD-347-5.0
A
B
Description
Part No.
190-3613
190-3615
190-3620
190-3625
9/16
4 RW TAPER - 7/8-14 NF
1-1/16
1-9/16
1-13/16
2-1/16
2-9/16
3-1/16
3-9/16
4-1/16
3/8
1/2
1-1/8
1-1/4
1-3/8
1-1/2
1-3/4
2
AD-134-1.1
AD-134-1.2
AD-134-1.3
AD-134-1.5
AD-134-1.7
AD-134-2.0
AD-134-2.2
AD-134-2.5
AD-134-3.0
AD-134-3.5
190-3211
190-3212
190-3213
190-3215
190-3217
190-3220
190-3222
190-3225
190-3230
190-3250
3/4-14
NPT
2-1/2
2-3/4
3
5/8
190-3630
190-3635
190-3640
190-3645
190-3650
190-3715
190-3720
190-3725
190-3730
190-3735
190-3740
190-3745
190-3750
190-4520
190-4530
190-4540
190-5410
190-5420
3/4
3-1/2
4
4-1/2
5
1.25
Hex
1
1-1/4
1-1/2
1-3/4
2-1/4
2-3/4
2-1/4
2-1/2
3
9/16
1-1/2
2
{
{
1-1/16
1-9/16
2-1/16
2-9/16
3-1/16
3-9/16
4-1/16
2-1/2
3
3-1/2
3/4-14
NPT
3-1/2
4
5 RW TAPER - 7/8-14 NF
3/8
1 /2
5/8
3/4
1
1-1/4
1-1/2
1-3/4
2-1/4
2-3/4
1-1/8
1-1/4
1-3/8
1-1/2
1-3/4
2
AD-135-1.1
AD-135-1.2
AD-135-1.3
AD-135-1.5
AD-135-1.7
AD-135-2.0
AD-135-2.2
AD-135-2.5
AD-135-3.0
AD-135-3.5
190-3311
190-3312
190-3313
190-3315
190-3317
190-3320
190-3322
190-3325
190-3330
190-3335
4-1/2
5
1
2
3
2
3
4
AD-45-2
AD-45-3
AD-45-4
1.25
Hex
4RW
5RW
5RW
4RW
1” Hex
1/4
1-1/8
AD-54-1
AD-54-2
2-1/4
2-1/2
3
1
1-1/2
2
2
2-1/2
3
7/8 Hex
AD-54-2.5*
AD-54-3
190-5430
190-5440
190-5520
190-5525
3
1
4
2
AD-54-4
3-1/2
AD-55-2
AD-55-2.5
AD-55-3*
AD-55-4
AD-55-5
AD-56-2
AD-64-1
AD-65-1
AD-74-1
AD-75-1
AD-75-2
AD-75-3.5*
AD-75-4*
5 RW TAPER - 1-12 NF
1-1/2
2-1/2
3/8
1/2
5/8
3/4
1
1-1/8
1-1/4
1-3/8
1-1/2
1-3/4
2
AD-105-1.1
AD-105-1.2
AD-105-1.3
AD-105-1.5
AD-105-1.7
AD-105-2.0
190-4311
190-4312
190-4313
190-4315
190-4317
190-4320
5RW
5RW
7/8 Hex
2
3
4
3
4
5
190-5540
190-5550
190-5620
190-6410
190-6510
190-7410
1.25
Hex
194-2085
1-3/8 D.
Barrel
Required
for 1-12 NF
Adapter
5RW
6RW
6RW
7RW
6RW
4RW
5RW
4RW
1” Hex
1” Hex
1” Hex
1” Hex
1-1/8
1/4
1/4
1/4
1/4
3/4
2-1/4
2-3/4
2
{
1-1/4
1-1/4
1-1/2
1-1/4
5 RW TAPER - 1-12 NF
1
2
190-7510
190-7520
1-1/2
1-3/4
2
2-1/4
2-3/4
2-1/4
2-1/2
2-3/4
3
AD-105-2.2
AD-105-2.5
AD-105-2.7
AD-105-3.0
AD-105-3.5
190-4322
190-4325
190-4327
190-4330
190-4335
7RW
5RW
1” Hex
1.25
Hex
3-1/2
4
{
3-1/2
* Not commonly stocked - other adapters available upon request
16
multi-spot barrel and clamp
TUFFALOY
101 SERIES HOLDERS (For 4 & 5 RW Tips)
STRAIGHT HOLDERS
Straight 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
HOLDER
clamp are silver plated.
Item Numbers for replacement
barrels and clamp parts are called
out on the drawings.
CLAMP 101-2:
PART NO. 194-2040
1/4 NPT HOSE CONNECTOR, 8241:
PART NO. 195-8241
HOLDER BARREL:
SINGLE-PORTED, 101-A:
PART NO. 194-2020
DOUBLE-PORTED, 101-B:
PART NO. 194-2025
Threaded adapters
for barrels can be
found on page 16.
FOR WATER TUBES
SEE PAGE 16
ADAPTER (1/2 NPT)
To determine distance adapter sticks out from holder,
deduct 1/2” from length of adapter selected. Water
tubes 1/2” longer than adapter will install approx-
imately flush with adapter face.
102 SERIES HOLDERS (For 6 & 7 RW Tips)
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
HOLDER
CLAMP 102-2:
PART NO. 194-2060
1/4 NPT HOSE CONNECTOR, 8241:
PART NO. 195-8241
CLAMP AND BARREL ARE SEPARATE PARTS
Adapters, water connectors and water tubes (see page 15 & 16)
are sold separately.
HOLDER BARREL:
SINGLE-PORTED, 102-A:
PART NO. 194-2070
DOUBLE-PORTED, 102-B:
PART NO. 194-2075
HOLDERS and CLAMPS
Number of Coolant Ports
Holders
For Tip
Sizes
FOR WATER TUBES
One Set
Descrip-
tion
Two Sets
Clamp
SEE PAGE 16
Part
No.
Descrip-
tion
Part
No.
Descrip-
tion
Part
No.
ADAPTER (3/4 NPT)
4 & 5 RW 101-A 194-2020 101-B 194-2025 101-2 194-2040
6 & 7 RW 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
To determine distance adapter sticks out from holder
deduct 3/4” from length of adapter selected. Water
tubes 3/4” longer than adapter will install approx-
imately flush with adapter face.
5 RW
SH-102-B 194-2085 102-2 194-2060
194-2085 (1-3/8 diameter barrel) only for 1-12 NF adapter
17
TUFFALOY
straight welding tip holders
GOLDCROWN® AND
STANDARD EJECTOR
GOLDCROWN
STANDARD
Tip
Socket
RW
Barrel
Dia.
Barrel
Length
Descrip-
tion
Part
No.
Descrip-
tion
Part
No.
HOLDERS
5/8
5/8
3/4
3/4
3/4
3/4
7/8
7/8
7/8
7/8
1
1
1
1
1
1
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
4
4
4
5
4
5
4
5
4
5
4
5
6
4
5
6
4
5
6
7
4
5
6
7
4
5
5
6
6
7
4
4
5
5
6
7
8
12
8
E-05084
E-05124
E-06084
E-06085
E-06124
E-06125
E-07084
E-07085
E-07124
E-07125
E-08084
E-08085
E-08086
E-08124
E-08125
E-08126
E-10084
E-10085
E-10086
E-10087
E-10124
E-10125
E-10126
E-10127
E-12084
E-12085
320-0100
320-0120
320-0140
320-0150
320-0160
320-0170*
320-0180
320-0190
320-0200
320-0210
320-0220
320-0230
320-0240*
320-0250
320-0260
320-0270*
320-0280
320-0290
320-0300*
320-0310
320-0320
320-0330
320-0340*
320-0350
320-0360*
320-0370
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.
8
12
12
8
8
12
12
8
8
8
12
12
12
8
8
8
SHE-08084
SHE-08085
SHE-08086
SHE-08124
SHE-08125
SHE-08126
SHE-10084
SHE-10085
SHE-10086
SHE-10087
SHE-10124
SHE-10125
SHE-10126
SHE-10127
SHE-12084
SHE-12085
321-0220
321-0230
321-0240*
321-0250
321-0260
321-0270*
321-0280
321-0290
321-0300*
321-0310
321-0320
321-0330
321-0340*
321-0350
321-0360
321-0370
8
Goldcrown premium holders are made of
extra-strength Class 2 alloy and are ground
and polished to yield greatest conductivity.
12
12
12
12
8
8
8
8
8
8
12
12
12
12
12
12
E-12085-A 320-0375* SHE-12085-A 321-0375*
ADAPTER SIZE FOR
THREADED BARRELS
E-12086
E-12086-A
E-12087
320-0380
320-0385
320-0390
320-0410
SHE-12086
SHE-12086-A
SHE-12087
SHE-12124
321-0380
321-0385
321-0390
321-0410
Part
No.
Descrip-
tion
THD
Size
Taper
E-12124
E-12124-A 320-0415* SHE-12124-A 321-0415*
E-12125 320-0420 SHE-12125 321-0420
E-12125-A 320-0425* SHE-12125-A 321-0425*
195-8550
195-8551
190-3615
8550
8551
AD-346-1.5
4RW
5RW
6RW
5/8-14 NPT
5/8-14 NPT
3/4-14 NPT
E-12126
E-12127
320-0440*
320-0450
SHE-12126
SHE-12127
321-0440*
321-0450
THESE ADAPTERS ARE SUPPLIED
Suffix ‘A’ in holder description denotes a threaded tip adapter is supplied
*Item not normally stocked
with the holder
Cross-section of holders with barrels 1 inch or more in diameter.
O-RING SEALS
EJECTOR TUBE
SELF-ADJUSTING WATER TUBE
EJECTOR BUTTON
BARREL LENGTH
Cross-section of holders with barrels 7/8 inch or less in diameter.
18
tip holders
TUFFALOY
GOLDSPOT
STANDARD
Tip
Socket
RW
GOLDSPOT® AND
STANDARD NON-EJECTOR
HOLDERS
Barrel
Dia.
Barrel
Length
Descrip-
tion
Part
No.
Descrip-
tion
Part
No.
5/8
5/8
3/4
3/4
3/4
3/4
7/8
7/8
7/8
7/8
1
1
1
1
1
1
1
4
4
4
5
4
5
4
5
4
5
4
4
5
5
6
4
4
5
5
6
4
4
5
5
6
7
4
4
5
5
6
7
4
4
5
5
6
7
4
5
5
6
7
8
12
8
N-05084
N-05124
N-06084
N-06085
N-06124
N-06125
N-07084
N-07085
N-07124
N-07125
N-08084
325-0100
325-0120*
325-0140
325-0150*
325-0160*
325-0170*
325-0180
325-0190*
325-0200
325-0210*
325-0220
8
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.
12
12
8
8
12
12
8
8
8
SHN-08084
SHN-08084-A
SHN-08085
326-0220
326-0225
326-0230
N-08084-A 325-0225
N-08085 325-0230
N-08085-A 325-0235* SHN-08085-A 326-0235*
N-08086
N-08124
N-08124-A 325-0255
N-08125 325-0260
N-08125-A 325-0265
N-08126
N-10084
N-10084-A 325-0285
N-10085 325-0290
N-10085-A 325-0295
N-10086
N-10087
N-10124
N-10124-A 325-0325* SHN-10124-A 326-0325*
N-10125
N-10125-A 325-0335
N-10126
N-10127
N-12084
N-12084-A 325-0365* SHN-12084-A 326-0365*
N-12085
N-12085-A 325-0375
N-12086
N-12087
N-12124
N-12125
8
8
325-0240*
325-0250
SHN-08086
SHN-08124
SHN-08124-A
SHN-08125
SHN-08125-A
SHN-08126
SHN-10084
SHN-10084-A
SHN-10085
SHN-10085-A
SHN-10086
SHN-10087
SHN-10124
326-0240*
326-0250
326-0255
326-0260
326-0265
326-0270*
326-0280*
326-0285
326-0290
326-0295
326-0300*
326-0310*
326-0320
12
12
12
12
12
8
8
8
8
8
1
1
1
325-0270*
325-0280*
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
Goldspot premium holders have barrels
of Class 2 alloy, ground and polished for
best conductivity.
325-0300*
325-0310*
325-0320
Examples of standard holders in use are
shown on page 22.
8
12
12
12
12
12
12
8
8
8
8
8
325-0330
SHN-10125
SHN-10125-A
SHN-10126
SHN-10127
SHN-12084
326-0330
326-0335
326-0340*
326-0350*
326-0360*
325-0340*
325-0350*
325-0360*
ADAPTER SIZE FOR
THREADED BARRELS
325-0370
SHN-12085
SHN-12085-A
SHN-12086
SHN-12087
SHN-12124
SHN-12125
326-0370
326-0375
326-0380*
326-0390
326-0410*
326-0420
Part
No.
Descrip-
tion
THD
Size
Taper
325-0380*
325-0390
325-0410*
325-0420
8
195-8550
195-8551
190-3615
8550
8551
AD-346-1.5
4RW
5RW
6RW
5/8-14 NPT
5/8-14 NPT
3/4-14 NPT
12
12
12
12
12
N-12125-A 325-0425* SHN-12125-A 326-0425*
N-12126
N-12127
325-0440*
325-0450*
SHN-12126
SHN-12127
326-0440*
326-0450*
THESE ADAPTERS ARE SUPPLIED
with the holder
Suffix “A” in holder description denotes a threaded tip adapter is supplied
*Item not normally stocked
Cross-section view of holders with barrels 1 inch or more in diameter.
19
TUFFALOY
nickel plated ejector holders
Barrel
Tip
Barrel
Descrip-
tion
Holder
Assy.
TUFFALOY NICKEL PLATED
EJECTOR HOLDERS
Diameter Socket RW Length
1
1-1/4
1
4
4
5
5
4
4
5
5
8
8
NHE-08084 319-0213
NHE-10084 319-0214
NEH-08085 319-0216
NEH-10085 319-0217
NEH-08124 319-0233
NEH-10124 319-0234
NEH-08125 319-0236
NEH-10125 319-0237
8
with self-adjusting water tubes
1-1/4
1
8
12
12
12
12
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.
1-1/4
1
1-1/4
Descrip-
tion
Holder
Assy.
1 Head
Assy.
2
3 Tube
Assy.
4 Water
Tube
5 Hose
Conn.
6 Barrel
O-Ring
7 Head
O-Ring
8 All
Thread
Barrel
NHE-08084
NHE-10084
NEH-08085
NEH-10085
NEH-08124
NEH-10124
NEH-08125
NEH-10125
319-0213
319-0214
319-0216
319-0217
319-0233
319-0234
319-0236
319-0237
195-0101
195-0101
195-0100
195-0100
195-0101
195-0101
195-0100
195-0100
001-213B
001-214B
001-216B
001-217B
001-233B
001-234B
001-236B
001-237B
195-0210
195-0210
195-0208
195-0208
195-0211
195-0211
195-0212
195-0212
195-0017
195-0017
195-0015
195-0015
195-0017
195-0017
195-0015
195-0015
195-8240
195-8240
195-8240
195-8240
195-8240
195-8240
195-8240
195-8240
195-8251
195-8251
037-0099
037-0099
195-8251
195-8251
037-0099
037-0099
037-0096
037-0096
037-0096
037-0096
037-0096
037-0096
037-0096
037-0096
195-0031
195-0031
195-0030
195-0030
195-0031
195-0031
195-0030
195-0030
20
tip holders
TUFFALOY
CLOSED-COUPLED HOLDERS
For use where welding space is limited. Standard body length is 3 inches. Other lengths are made on request; minimum
length 2 inches.
60°
Body
Dia.
Tip
Socket
Descrip-
tion
Part
No.
3/4
7/8
7/8
1
1
1-1/4
1-1/4
1-1/2
1-1/2
4RW
4RW
5RW
4RW
5RW
4RW
5RW
4RW
5RW
N-06034
N-07034
N-07035
N-08034
N-08035
N-10034
N-10035
N-12034
N-12035
330-0140
330-0180
330-0190
330-0220
330-0230
330-0280
330-0290
330-0360*
330-0370*
BARREL LENGTH 3
5/16 O.D. TUBE
*Item not normally stocked
RW TAPER
SOCKET
1/4 O.D. ADJUSTABLE
WATER TUBE
SHANK LENGTH 4-1/8
ADJUSTABLE WATER TUBE USE
It is very 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 are used to deflect incoming coolant water to the full extent of the water hole in the electrode.
Before 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.
21
TUFFALOY
offset holders
BARREL LENGTH
HOLE DIA. (TEE CONNECTOR)
2-1/4
°
AD-585-90E, for 5RW Tip
Part No. 190-9590
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.
AD-584-30, for 4RW Tip
Part No. 190-8430
AD-585-30, for 5RW Tip
Part No. 190-8530
SHANK DIA.
HOLDERS
TEE CONNECTORS
ADAPTERS TO CHOOSE FROM
Barrel Barrel
Dia. Length
Descrip-
tion.
Part
No.
Hole Shank
Descrip-
tion
Part
No.
Tip
Angle
Descrip-
tion
Part
No.
Dia.
Dia.
Socket Degrees
1
8
8
8
8
8
8
8
8
8
N-08085-A 325-0235
N-10085-A 325-0295
N-10085-A 325-0295
N-10085-A 325-0295
N-10085-A 325-0295
N-10085-A 325-0295
N-12085-A 325-0375
N-12085-A 325-0375
N-12085-A 325-0375
1
1
1
1
T-1-1
T-1
T-1
T-125
T-125
T-125
T-15
T-15
T-15
192-1100
192-1000
192-1000
192-1250
192-1250
192-1250
192-1500
192-1500
192-1500
4RW
4RW
5RW
5RW
6RW
90
30
90
30
90
AD-584-90 190-8490
AD-584-30 190-8430
AD-585-90 190-8590
AD-585-30 190-8530
AD-586-90 190-8690
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/2
1-1/2
1-1/2
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/2
1-1/2
1-1/2
1-1/4
1-1/4
1-1/4
1-1/2
1-1/2
1-1/2
AD-584-90, for 4RW Tip
Part No. 190-8490
AD-585-90, for 5RW Tip
Part No. 190-8590
welder arms
TUFFALOY
Class 2 spot welding machine arms made by Tuffaloy reduce set up time and give longer life.
Electrode 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
A
Arm
B
Hole
C
Arm
threads are cut. This provides greatly increased thread life.
Descrip-
tion
Part
No.
Standard arm configurations are shown in the table. Special arms
are also available.
Diameter Diameter* Length
12
16
SH-7320-1
SH-7320-2
630-7321
630-7322
2
1
22
standard offset holders
TUFFALOY
STANDARD OFFSET HOLDERS
OFFSET 2 OR 4
TUFFALOY 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.
2
(MAX.)
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.
HEAD HEIGHT 2 1/4” ON
EJECTOR-TYPE MODEL
ADAPTERS SUPPLIED:
4RW: AD-584
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
prefix from ‘ON’ to ‘OE’. Example: OE-874-290.
5RW: AD-585
30°
TWO-INCH OFFSET HOLDERS
3/4”
SHANK DIA.
7/8”
SHANK DIA.
1”
1-1/4”
SHANK DIA.
1-1/2”
SHANK DIA.
Adapter
Tip
Socket
Socket
Angle
SHANK DIA.
Descrip-
tion
Part
No.
Descrip-
tion
Part
No.
Descrip-
tion
Part
No.
Descrip-
tion
Part
No.
Descrip-
tion
Part
No.
4RW
4RW
5RW
5RW
30°
90°
30°
90°
ON-754-230 335-1300 ON-874-230 335-1400*
ON-754-290 335-1310* ON-874-290 335-1410*
ON-755-230 335-1350* ON-875-230 335-1450*
ON-755-290 335-1360* ON-875-290 335-1460*
ON-14-230
ON-14-290
ON-15-230
ON-15-290
335-1000 ON-1254-230 335-1100
335-1010 ON-1254-290 335-1110
335-1050 ON-1255-230 335-1150
335-1060 ON-1255-290 335-1160
ON-154-230 335-1200*
ON-154-290 335-1210*
ON-155-230 335-1250*
ON-155-290
335-1260
FOUR-INCH OFFSET HOLDERS
4RW
4RW
5RW
5RW
30°
90°
30°
90°
ON-754-430 335-1320* ON-874-430 335-1420*
ON-14-430
ON-14-490
ON-15-430
ON-15-490
335-1020 ON-1254-430 335-1120
ON-154-430 335-1220*
ON-154-490 335-1230*
ON-754-490 335-1330* ON-874-490 335-1430*
ON-755-430 335-1370* ON-875-430 335-1470*
ON-755-490 335-1380* ON-875-490 335-1480*
335-1030 ON-1254-490 335-1130
335-1070 ON-1255-430 335-1170
335-1080 ON-1255-490 335-1180
ON-155-430
ON-155-490
335-1270
335-1280
*May not be in stock
USING STANDARD HOLDERS
Figure 2: An offset holder with
bent tip is used to weld close to
the corner of a box section.
Figure 3: A universal holder
Figure 4: A platen set-up using
platen-mounted standard tips
under an Equa-Press dual holder.
Figure 1: An offset holder over a
low-profile paddle-type holder
that works in confined spaces.
(economical because it adjusts
to many jobs) over a close-
coupled holder.
23
TUFFALOY
variable-offset holders
VARIABLE-OFFSET HOLDERS
Shank
Dia.
Descrip-
tion
Part
No.
1
SH-7223
SH-7224
SH-7225
345-7223
345-7224
345-7225
1-1/4
1-1/2
4 MIN.
3-1/2
5 MAX.
VARIABLE 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
by a locking-wedge device in the holder.
Tips are made in one and two-piece designs. The one-piece
tips are offered with the nose designs shown. The two-piece
tips are made up by combining the shanks shown here with
Tuffcap caps (normally used with No. 5 RW size 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.
STRAIGHT-SHANK TIPS
Type
of Tip
Nose Length Descrip-
Part
No.
‘A’
tion
Pointed
Offset
15° Dome
30° Dome
Pointed
Offset
15° Dome
30° Dome
1”
1”
1”
1”
2”
2”
2”
2”
SE-4408-1 170-4408
SE-4409-1 170-4409
SE-4410-1 170-4410
SE-4411-1 170-4411
SE-4408-2 170-4418
SE-4409-2 170-4419
SE-4410-2 170-4420
SE-4411-2 170-4421
STRAIGHT-SHANK TUFFCAP SHANKS
Tuffcap
Nose
Length Angle
‘A’
Descrip-
tion
Part
No.
Cap
Type
Male
Male
Female
Female
3/4”
3/4”
1”
90°
15°
90°
15°
SE-4412 170-4422
SE-4413 170-4423
SE-4414 170-4424
SE-4415 170-4425
1”
24
paddle-type holders
TUFFALOY
OFFSET 4
TUFFALOY PADDLE-TYPE HOLDERS
AND SOCKET-TYPE TIPS
11/16
This holder is for welding in very restricted areas. It provides a very
low 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
available in Class 1, Class 2, Class 3 alloy, or Z alloy.
Shank Descrip-
Dia.
Part
No.
tion
3/4
7/8
1
P-750-490 345-0750
P-870-490 345-0870
P-100-490 345-1000
SHANK
LENGTH
3
The four socket-type tips shown here can be used in special welding
fixtures and dies as well as in the paddle-type holders.
1-1/4 P-120-490 345-1200
1-1/2 P-150-490 345-1500
FLAT FACED
TRUNCATED CONE
Class 1 SE-3101-1
Part No. 170-3101-1
Class 2 SE-3101
Part No. 170-3101
Class 3 SE-3113
OFFSET
Class 1 SE-3102-1
Part No. 170-3102-1
Class 2 SE-3102
Part No. 170-3102
Class 3 SE-3123
RADIUS FACED
Class 1 SE-3110-1
Part No. 170-3110-1
Class 2 SE-3110
Part No. 170-3110
Class 3 SE-3133
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. 170-3113
ZIRC SE-3101-Z
Part No. 170-3123
ZIRC SE-3102-Z
Part No. 170-3133
ZIRC SE-3110-Z
Part No. 170-3099-Z
Part No. 170-3101-Z
Part No. 170-3102-Z
Part No. 170-3110-Z
OFFSET 4
3/4
TUFFALOY HEAVY-DUTY
PADDLE-TYPE HOLDERS AND TIPS
TUFFALOY 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 low 3/4-in. and the shank length is a
usable 4 inches.
Shank Descrip-
Part
No.
Dia.
tion
1
SH-7194 345-7194
SH-7195 345-7195
SH-7196 345-7196
Three low-profile 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.
SHANK
LENGTH
4
1-1/4
1-1/2
TRUNCATED CONE
SE-3247
Part No. 170-3247
AT FACED
3249
t No. 170-3249
25
TUFFALOY
high pressure welding
HIGH PRESSURE TIPS
Spot 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.
FLAT FACED
TRUNCATED CONE
DOME NOSED
Size 2
‘A’
Description Part No.
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 1 PMB-2503
Part No. 180-2103
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
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 are 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 PM holders.
1-3/4
5-5/16
3-1/2
Barrel Descrip-
Part
No.
Size
Dia.
tion
1
1
1
2
2
1
4511
4512
4513
4521
4522
350-4511
1-1/4
1-1/2
1-1/4
1-1/2
350-4512
350-4513
350-4521
350-4522
26
high pressure welding
TUFFALOY
1
BODY IS 2” WIDE
BODY IS 1-1/2” WIDE
2-3/8
3/4
1-5/8
7
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
PM HOLDERS
TUFFALOY PM holders are mounted directly to press-
type welder platens, or are used as components of
special weld fixturing.
Platen Mounting: PM holders bolt easily to the
platen T-slots at any desired location, in a minimum
of time (no intermediary device is required). Big half-
inch mounting bolts may be used to assure good
conductivity. They are the first such standard, stocked
holders to be made available. They come in two sizes,
to match standard T-slot spacing, and to hold the 2
sizes of tips shown. The small size 1 PM 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.)
27
TUFFALOY
platen-mounted holders
PM HOLDERS
TUFFALOY 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 3-1/2” spacing. 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.
STANDARD TIP PM HOLDERS
Size 1 (Small)
Size 2 (Large)
RW Tip
Socket
Descrip-
Part
No.
Descrip-
Part
No.
tion
tion
4
5
6
7
4560
4561
4562
4563
350-4560
350-4561
350-4562
350-4563
4570
4571
4572
4573
350-4570
350-4571
350-4572*
350-4573
*Item not normally stocked
Size 2 PM Holder (3/4-in. mounting bolts)
FOR THREADED ELECTRODES
This Style Only
Thread Size
Size 1
Size 2
5/8-11
3/4-10
350-4580
350-4581
350-4590
350-4591
THREAD SIZE
(PIPE THREAD
ON REQUEST)
7/8-14 &
1-12 ONLY
FOR THREADED ADAPTERS
1-1/2" HEX.
1-3/4"
Thread Size
Size 1
Size 2
7/8-14
1-12
350-4582
350-4583
350-4592
350-4593
1/2"
See adapters page 16
4-1/4"
For 1“ Dia. Electrodes
For 1-1/2” Dia. Electrodes
PM Holders
T-Slot Spacing
Holder
Size
Description Part No. Description Part No.
3-1/2
1PM
4515
350-4515
350-4526
7/8
BODY IS 2” WIDE
2-3/8
BODY IS
1-1/2” WIDE
1-5/8
7
Size 1 PM Holder
Size 2 PM Holder
28
nut and stud welding
TUFFALOY
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.
STUD ELECTRODES
With 10W Face
Refractory -
Item Number
Descrip-
tion
Part
No.
A
B
C
.150
.164
.190
.216
1/4
400
401
402
403
404
405
406
506
507
509
510
175-4001
175-4011
175-4021
175-4031
175-4041
175-4051
175-4061
175-5061
175-5071
175-5091
175-5101
175-4001-10W
175-4011-10W
175-4021-10W
175-4031-10W
175-4041-10W
175-4051-10W
175-4061-10W
175-5061-10W
175-5071-10W
175-5091-10W
175-5101-10W
This style holder
found at bottom
of page 27
2-1/4
1
5/16 & 8mm
3/8
6mm
7mm
9mm
10mm
3/8
7/16
1/2
9/16
5/8
11/16
3/4
10mm
12mm
436
437
438
439
440
441
442
510-2
512-2
175-4361
175-4371
175-4381
175-4391
175-4401
175-4411
175-4421
175-5102
175-5122
175-4361-10W
175-4371-10W
175-4381-10W
175-4391-10W
175-4401-10W
175-4411-10W
175-4421-10W
175-5102-10W
175-5122-10W
2-3/4
1-1/2
This style holder found
at top of page 29
ELECTRODES
SELF-PILOTED-NUT ELECTRODES
Stud Electrodes
E
Pin
F
G
With 10W Face
Refractory -
Item Number
Tuffaloy stud electrode tips
are for projection-welding
screws, bolts or pins,
whether they pass through
the sheet or are to be
Descrip-
Electrode Electrode
tion
Part
No.
For Nut
Size
Length Length Diameter
.164
.190
.216
1/4
3/16
3/16
1/4
411
412
413
414
415
416
606
607
609
610
175-4111
175-4121
175-4131
175-4141
175-4151
175-4161
175-6061
175-6071
175-6091
175-6101
175-4111-10W
175-4121-10W
175-4131-10W
175-4141-10W
175-4151-10W
175-4161-10W
175-6061-10W
175-6071-10W
175-6091-10W
175-6101-10W
5/16
2-1/4
1
5/16 & 8mm 5/16
attached directly to its face.
3/8
6mm
7mm
9mm
10mm
3/8
1/4
5/16
3/8
Nut Electrodes
Tuffaloy projection weld nut
electrodes are designed for
either self-piloted or non-
piloted nuts. The pilots of the
non-piloted-nut electrodes
are spring-loaded so they
can’t interfere with the
3/8
3/8
7/16
1/2
9/16
5/8
11/16
3/4
10mm
12mm
3/8
3/8
7/16
7/16
1/2
1/2
5/8
456
457
458
459
460
461
462
175-4561
175-4571
175-4581
175-4591
175-4601
175-4611
175-4621
175-4561-10W
175-4571-10W
175-4581-10W
175-4591-10W
175-4601-10W
175-4611-10W
175-4621-10W
175-6102-10W
175-6122-10W
2-3/4
1-1/2
3/8
7/16
610-2 175-6102
612-2 175-6122
contacting of nut and sheet
under welding pressure.
NON-PILOTED-NUT ELECTRODES
J
Pin
K
L
With 10W Face
Refractory -
Item Number
Descrip-
Electrode Electrode
tion
Part
No.
For Nut
Size
Diameter Length Diameter
.164
.190
.216
0.18
0.215
0.24
0.275
0.345
0.405
0.261
0.3
421
422
423
424
425
426
706
707
709
710
175-4211 175-4211-10W
175-4221 175-4221-10W
175-4231 175-4231-10W
175-4241 175-4241-10W
175-4251 175-4251-10W
175-4261 175-4261-10W
175-7061 175-7061-10W
175-7071 175-7071-10W
175-7091 175-7091-10W
175-7101 175-7101-I0W
1/4
5/16 & 8mm
3/8
6mm
7mm
9mm
10mm
2-1/4
1
Welding a stud through a hole in
sheet metal.
0.385
0.425
Welding a stud directly to face of
sheet metal.
3/8
7/16
1/2
9/16
5/8
10mm
12mm
0.437
0.562
0.625
0.687
0.75
0.453
0.595
476
477
478
479
480
175-4761 175-4761-10W
175-4771 175-4771-10W
175-4781 175-4781-10W
175-4791 175-4791-I0W
175-4801 175-4801-10W
Self-piloted nut aligns itself with
the hole in sheet.
2-3/4
1-1/2
Non-piloted-nut is guided by
specially designed electrode.
710-2 175-7102 175-7102-10W
712-2 175-7122 175-7122-10W
29
TUFFALOY
nut and stud welding
1-3/4
ELECTRODE HOLDERS
U.S. Pat. No. 3,504,159 Canada Pat. No. 858,060
Several standard electrode holders are manufactured by Tuffaloy to
accommodate all the Tuffaloy stud-and nut electrode tips.
Straight Holders - Tuffaloy
straight 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 1“ Dia.
Electrodes
For 1-1/2” Dia.
Electrodes
Straight
Holders
Barrel
A
B
Dia. Length
Descrip-
tion
Part
No.
Descrip-
tion
Part
No.
Diameter
5-5/8
1
1-3/4 5-5/8
1-3/4 5-5/8
1-3/4 5-5/8
2
2
2
4530
4531
4532
350-4530
350-4531
350-4532
1-1/4
1-1/2
1
1-1/4
1-1/2
5-3/4
5-3/4
5-3/4
4535
4536
4537
350-4535
350-4536
350-4537
3-1/2
Straight Holder
ARCTIC HOLDERS
ARCTIC STUD ELECTRODES
A
B
C
Descrip-
tion
Part Number
Shank Size
For Stud
Diameter
Electrode Electrode
Arctic Electrodes - The Arctic system is a compact stud-and-
nut electrode with internal water cooling. Also available with
optional air expulsion and platen mounts.
Length
Diameter
0.150
0.164
0.190
0.216
1/4
115
116
119
122
125
131
138
144
106
107
109
110
175-1151-X
175-1161-X
175-1191-X
175-1221-X
175-1252-X
175-1312-X
175-1382-X
175-1442-X
175-1061-X
175-1072-X
175-1092-X
175-1102-X
3
1-1/4
Patent Pending
5/16 & 8mm
3/8
7/16
6mm
7mm
9mm
10mm
1/2
9/16
5/8
11/16
12mm
150
156
163
169
112
175-1503-X
175-1563-X
175-1633-X
175-1693-X
175-1123-X
3
1-1/2
ARCTIC NON-PILOTED-NUT ELECTRODES
H
J
K
L
Descrip- Part Number
For Nut
Pilot
Electrode Electrode
tion
Shank Size
Diameter Diameter Length Diameter
0.164
0.190
0.216
1/4
5/16 & 8mm
3/8
6mm
7mm
9mm
10mm
0.180
0.215
0.240
0.275
0.345
0.405
0.261
0.300
0.385
0.425
216
219
222
225
231
238
206
207
209
210
175-2162-X
175-2192-X
175-2222-X
175-2252-X
175-2312-X
175-2382-X
175-2062-X
175-2072-X
175-2092-X
175-2102-X
4
4
1-1/4
1-1/2
7/16
1/2
9/16
12mm
0.562
0.625
0.687
0.595
244
250
256
212
175-2443-X
175-2503-X
175-2563-X
175-2123-X
30
automatic nut feeder system components
TUFFALOY
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
threaded 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.
HEADS
Part
Number
Hole
Dia.
A
B
C
Dia.
Copper-Tungsten
Faced Heads
Pin Size
Thread
175-8004
175-8005
175-8006
175-8007
175-8008
175-8009
.197
.236
.276
.315
.354
.394
4mm
5mm
6mm
7mm
8mm
9mm
175-8004-10W
175-8005-10W
175-8006-10W
175-8007-10W
175-8008-10W
175-8009-10W
M18
1.0
175-8010
175-8011
175-8012
175-8013
.432
.472
.512
.551
10mm
11mm
12mm
13mm
175-8010-10W
175-8011-10W
175-8012-10W
175-8013-10W
M22
M26
1.125”
1.250”
175-8014
.588
14mm
175-8014-10W
PINS
Part
A
B
C
Pilot Dia.
Number
Nut
OAL
Base
12mm
16mm
195-3004
195-3005
195-3006
195-3007
195-3008
195-3009
195-3010
195-3011
195-3012
195-3013
4mm
5mm
6mm
7mm
8mm
9mm
10mm
11mm
12mm
13mm
1.12”
1.17”
1.23”
1.24”
1.25”
1.19”
1.37”
1.38”
1.40”
1.37”
.185
.224
.264
.303
.340
.380
.422
.458
.500
.539
A
Pilot
195-3014
195-3015
14mm
15mm
1.50”
1.52”
.815
.815
.580
.620
BODIES
Part
Number
A
OAL
B
Dia.
C
D
Taper
Description
Thread
TDH-25A
TDH-25C
TDH-30A
TDH-35A
301-0004
301-0005
301-0015
301-0020
1.77”
1.97”
1.97”
1.97”
1”
1”
1.125”
1.125”
18mm
18mm
22mm
26mm
#4
#5
#5
#5
UPPER ELECTRODE
Part
Number
A
ID
B
OAL
C
Dia.
D
Taper
Description
TNFD 16-M5-16-3
TNFD 20-M6-16-3
TNFD 20-M8-16-3
TNFD 20-M10-16-3
TNFD 20-M12-16-3
186-0101
186-0102
186-0103
186-0104
186-0105
5mm
6mm
7.5mm
10mm
12mm
.625”
.75”
.75”
.75”
.75”
2.36”
5RW
31
TUFFALOY
automatic nut feeder system components
GH SERIES NUT WELDING HEADS
LENGTH
COPPER TUNGSTEN O.D.
HEX
INSERT I.D.
SIZE
175-GH-2 Series 175-GH-3 Series 175-GH-4 Series
Insert I.D.
175-GH-2 Series 175-GH-3 Series 175-GH-4 Series
Insert I.D.
Length
Tungsten OD
Hex Size
0.875
0.875
1.000
1.250
1.125
1.500
1.500
0.875
0.875
1.000
1.250
1.375
1.125
1.500
1.500
1.000
1.375
1.000
175-GH-2-188
175-GH-2-193
175-GH-2-197
175-GH-3-188
175-GH-3-193
0.188
0.193
0.197
0.200
0.212
0.218
0.239
0.240
(6mm) 0.242
0.245
0.247
0.250
0.251
0.252
0.254
0.258
0.262
0.263
0.264
0.272
0.273
0.275
0.277
0.280
0.282
0.287
0.312
(8mm) 0.317
0.322
0.325
0.326
0.332
0.337
0.342
0.347
0.351
0.352
0.354
0.357
0.359
175-GH-2-368
175-GH-2-372
0.368
0.372
0.392
(10mm) 0.397
0.412
0.417
0.423
0.425
0.427
0.430
0.432
0.437
0.445
0.447
0.452
0.465
0.467
0.470
0.472
(12mm) 0.480
0.504
0.507
0.508
0.509
0.512
0.517
0.522
0.538
0.542
0.547
0.548
0.552
0.557
0.587
0.592
0.632
0.656
0.667
0.677
175-GH-3-372
175-GH-3-392
175-GH-3-397
175-GH-3-412
175-GH-3-417
175-GH-3-423
175-GH-3-425
175-GH-3-427
175-GH-3-430
175-GH-3-432
175-GH-3-437
175-GH-3-445
175-GH-3-447
175-GH-3-452
175-GH-3-465
175-GH-3-467
175-GH-3-470
175-GH-3-472
175-GH-3-480
175-GH-3-504
175-GH-3-507
175-GH-3-508
175-GH-3-200
175-GH-2-212
175-GH-2-218
175-GH-2-239
175-GH-2-240
175-GH-2-242
175-GH-2-245
175-GH-3-242
175-GH-3-245
175-GH-3-247
175-GH-2-250
175-GH-2-252
175-GH-2-258
175-GH-2-263
175-GH-3-251
175-GH-3-254
175-GH-3-262
175-GH-3-264
175-GH-3-272
175-GH-3-273
175-GH-2-272
175-GH-2-273
175-GH-2-275
175-GH-2-277
175-GH-2-280
175-GH-2-282
175-GH-2-287
175-GH-2-312
175-GH-4-509
175-GH-3-512
175-GH-3-517
175-GH-3-522
175-GH-3-538
175-GH-3-542
175-GH-3-547
175-GH-3-548
175-GH-3-552
175-GH-3-557
175-GH-3-587
175-GH-3-592
175-GH-3-632
175-GH-3-656
175-GH-3-312
175-GH-3-317
175-GH-3-322
175-GH-2-322
175-GH-2-325
175-GH-4-325
175-GH-4-351
175-GH-3-326
175-GH-3-332
175-GH-3-337
175-GH-2-342
175-GH-2-347
175-GH-3-347
175-GH-3-351
175-GH-3-352
175-GH-2-352
175-GH-2-354
175-GH-2-357
175-GH-2-359
175-GH-4-667
175-GH-4-677
175-GH-3-357
32
5 rw stud electrodes
TUFFALOY
These series of Stud electrodes are made from RWMA Class 2 material with TUFFALOYS’ 10W (copper tungsten) on the
weld 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.
INSULATOR
Screw
Thread Size
ID.
A
Length
B
Part
Number
.218
.243
.256
.319
.381
.400
175-0316-4032-10W
175-0316-40062-10W
175-0316-4042-10W
175-0316-4052-10W
175-0316-4062-10W
175-0316-40102-10W
6mm
0.250
0.312, 8mm
0.375
1”
2”
1”
10mm
.218
.243
.256
.319
.381
.400
175-0316-4031-10W
175-0316-4006-10W
175-0316-4041-10W
175-0316-4051-10W
175-0316-4061-10W
175-0316-4010-10W
6mm
0.250
0.312, 8mm
0.375
10mm
0.437
12mm
0.500
.444
.479
.506
.569
.652
.694
.777
175-1313-4372-10W
175-1313-40122-10W
175-1313-4382-10W
175-1313-4392-10W
175-1313-4402-10W
175-1313-4412-10W
175-1313-4422-10W
0.625
0.437
12mm
0.500
.444
.479
.506
.569
.652
.694
.777
175-1313-4371-10W
175-1313-4012-10W
175-1313-4381-10W
175-1313-4391-10W
175-1313-4401-10W
175-1313-4411-10W
175-1313-4421-10W
2”
0.625
BACKUP ELECTRODES FOR UPPERS
186-0313-10W
186-1313-10W
33
TUFFALOY
multiple welding
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.
They’re 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 you’ll
probably 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 they’ll design a set-up
to do it.
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 stroke. 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 1/2” or 5/8” diameter male Tuffcap caps, or 4 RW tips (5/8” cap
sockets are standard).
HEAVY-DUTY adapters have shanks from 5 to 7 RW size, tip spacing to
6 inches, tip sockets for 1/2” or 5/8” diameter male Tuffcap caps, or
4 or 5 RW tips (4 RW sockets are standard). These adapters have a
deeper, stronger body.
Two low-height 5/8” dia. cap-type tips are shown below. They are
recommended for use in these adapters. Other standard caps, both
5/8” & 1/2” dia., are tabled on the next page. You must specify the
size tip sockets you want, or the standard socket will be supplied.
Tip
Shank Descrip- Spacing
Socket
Taper
Style
Taper
tion*
Range
(inches)
4RW
4RW
5RW
5RW
TT-1408 1-1/4 to 2 4RW 5RW 4CT 5CT
TT-1416 2 to 4 4RW 5RW 4CT 5CT
TT-1508 1-1/2 to 2 4RW 5RW 4CT 5CT
LIGHT
Duty
TT-1516
2 to 4
4RW 5RW 4CT 5CT
TRUN-6332
(P2)
5RW
5RW
6RW
6RW
7RW
7RW
TT-15516
TT-15524
TT-15616
TT-15624
TT-15716
TT-15724
2 to 4
4 to 6
2 to 4
4 to 6
2 to 4
4 to 6
4RW 5RW 4CT 5CT
4RW 5RW 4CT 5CT
4RW 5RW 4CT 5CT
4RW 5RW 4CT 5CT
4RW 5RW 4CT 5CT
4RW 5RW 4CT 5CT
HEAVY
Duty
*When ordering, also state exact tip spacing and tip
socket size, Example: TT - 1508 - 1-1/2 - 5CT. (5CT means
5/8” diameter cap, 4CT means 1/2” diameter cap.)
FLAT FACED SE-6296
(Part No. 186-0523)
HEAVY DUTY
34
multiple welding
TUFFALOY
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 1” or 1-1/2”
spacing between barrels, and with tip sockets to accept
either male Tuffcap caps (5/8” dia.) 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 barrels.
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 rod.
Equatip holders can be used with forces up to 1000 lbs.
EQUATIP HOLDERS
For 5/8” Dia.
Tuffcap Caps
For No. 4
RW Tips
Tip Spacing &
Mounting Style
Descrip-
tion
Part
No.
Descrip-
tion
Part
No.
ONE-INCH SPACING:
1-in. shank
5/8” DIA. TUFFCAP CAPS (5 CT)
4050
4051
4052
4053
4054
350-4050
350-4051
350-4052
350-4053
350-4054
4055
4056
4057
4058
4059
350-4055
350-4056
350-4057
350-4058
350-4059
1-1/4-in. shank
1-1/2-in. shank
5RW adapter
Nose Alloy Descrip-
Part
No.
Style
Class
tion
Pointed
1
2
1
2
1
2
1
2
TA-15
TA-25
TB-15
TB-25
TC-15
TC-25
TD-15
TD-25
111-0015
112-0025
113-0015
114-0025
115-0015
116-0025
117-0015
118-0025
Cylinder adapter*
4
1-1/2-INCH SPACING:
1-in. shank
Dome
Flat
4150
4151
4152
4153
4154
350-4150
350-4151
350-4152
350-4153
350-4154
4155
4156
4157
4158
4159
350-4155
350-4156
350-4157
350-4158
350-4159
1-1/4-in. shank
1-1/2-in. shank
5RW adapter
Offset
BODY
Cylinder adapter*
IS 1”
THICK
Those caps are fully dimensioned on page 6.
*Without clamp
For light-duty welding
EQUATIP ADAPTER
2-7/8
7/16
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
5/8” apart. Its straight tips
are TUFFCAP caps,
1/2” DIA. TUFFCAP CAPS (4 CT)
Nose Alloy Descrip-
Style
Part
No.
Class
tion
Pointed
1
2
1
2
1
2
1
2
TA-14
TA-24
TB-14
TB-24
TC-14
TC-24
TD-14
TD-24
111-0014
112-0024
113-0014
114-0024
115-0014
116-0024
117-0014
118-0024
Dome
Flat
Offset
1
4045, Part No. 350-4045-5RW
4046, Part No. 350-4046-4RW
1/2” in diameter.
OR
1/2
1/2
Those caps are fully dimensioned on page 6.
1-1/2
35
TUFFALOY
multiple welding
EQUA-PRESSTM
DUAL TIP
HOLDERS
U.S. Pat. No. 2,979,599
Canada Pat. 637470
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,
regardless of variations in work thickness, or electrode
wear (up to 3/16”). The two tip-holding barrels are sliding
pistons, whose movements are controlled by a mechanical
equalizing slide in the housing (see cutaway drawings).
The spring’s only function is to return the barrels to a fully
extended position when there 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 rocker
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.
Standard Design
Short Design
Mounting Style Descrip-
Part
No.
Descrip-
tion
Part
No.
tion
1-in. shank
1-1 /4-in. shank
1-1 /2-1n. shank
Platen
4010
4011
4012
4013
350-4010
350-4011
350-4012
350-4013
4015
4016
4017
4018
350-4015
350-4016
350-4017
350-4018
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
multiple welding
TUFFALOY
LOWER ELECTRODE
1-1/2 SQ.
5
4
A Case History: Projection
welding brackets to
automotive frame
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
current bypassing weld
projections. Two standard
swivel tips make four welds,
two per part.
LOWER ELECTRODES
Shank Diameter
Description
Part No.
1
4020
4021
4022
350-4020
350-4021
350-4022
assemblies is twice as fast
with an Equa-Press dual tip
holder. Lower welding
fixture acts as an inspection
device, so warped parts are
discovered before welding.
Inspection time and scrap
loss are both reduced.
1-1/4
1-1/2
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’t require tips on the lower side. They are water-cooled.
A
4 RW-Special
5RW-Special
5 RW
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
standard TUFFCAP caps.
2
4
BODY
IS 1”
THICK
4
LOWER ELECTRODE
STANDARD LOWER HOLDER - 2” SPACING 5 RW
Lower Holder
Shank Diameter
Description
Part No.
1
4030
4031
4032
350-4030
350-4031
350-4032
1-1/4
1-1/2
SPECIAL LOWER ELECTRODES
Shank
Diameter
(inches)
A
Style
Description*
Tip Spacing
Range (inches)
4” Body
1
4030
4031
4032
8030
8031
8032
1-1/4 to 2-7/8
1-1/4 to 2-7/8
1-1/4 to 2-7/8
3 to 6
In this drawing, two studs
are projection 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.
1-1/4
1-1/2
1
1-1/4
1-1/2
8” Body
3 to 6
3 to 6
* When ordering specify center distance and
either 4RW or 5RW sockets
37
TUFFALOY
multiple welding
TRISPACERTM TRIPLE TIP HOLDER
U.S. Pat. No. 3,558,848
TRISPACER HOLDER
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.
Descrip-
tion
Part
No.
Mounting Style
1-in. shank
1-1/4-in. shank
1-1/2-in. shank
Platen
4040
4041
4042
4043
350-4040
350-4041
350-4042
350-4043
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 current-carrying 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.
SYMBOLS
Maximum Triangle Size
Straight-Tip Triangle Size
Minimum Triangle Size
Maximum Straight-Line Spacing
ndicates the wide range of
rns which can be made with
er by using straight, standard
ecial bent tips.
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 Trispacer. It comes in three shank
diameter models.
4
1/2
2
3 DIA.
PLATEN
DIMENSIONS
1/2 x 3-1/2 x 7
3
LOWER ELECTRO
Shank Descrip-
Pa
N
Dia.
tion
1
4025
4026
4027
350-
350-
350-
1-1/4
1-1/2
1-7/8
5 RW TAPER
38
fast-follow-up holders
TUFFALOY
U.S. Pat. No. 3,632,958 Canada Pat. No. 902,189
TUFFALOY fast-follow-up (low inertia) holders solve the
problem of maintaining adequate weld pressure on rapidly
collapsing projection welds-with fewer set-up problems and
reduced maintenance.
These 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, it’s easily available (4) spring forces
available are clearly indicated, so it’s 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’t 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
through the outer body, two split
contact rings, tapered tip socket,
and to the electrode.
C
D
B
A
Compression
2 marks
Compression
3 marks
Compression
1 mark
No external
Compression
For every one-eighth of an inch that a fast-follow-up is compressed when
setting up, a known amount of force is provided, to quickly follow up any
reduction in work thickness. Example: at position B, a type MH spring would
delivery 310 lb, at C, 440 lb, etc.
FAST-FOLLOW-UP FORCE CHART (LBS.)
Spring
Type
1/8-in.
1/4-in.
3/8-in.
1/2-in.
Compression Compression Compression Compression
M (300 lbs. max.)
MH (680 lbs. max.)
H (1300 lbs. max.)
140
310
600
200
440
840
250
560
1070
300
680
1300
300 LBS MAX.
(M SPRING)
680 LBS. MAX.
(MH SPRING)
1300 LBS. MAX.
(H SPRING)
Mounting
Style
Descrip-
Part
No.
Descrip-
Part
No.
Descrip-
Part
No.
tion
tion
tion
1” Shank
4620
4623
4626
4629
350-4620
350-4623
350-4626
350-4629
4621
4624
4627
4630
350-4621
350-4624
350-4627
350-4630
4622
4625
4628
4631
350-4622
350-4625
350-4628
350-4631
1-1/4” Shank
1-1/2” Shank
Platen-Mtd.
39
TUFFALOY
bar stock
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.
Tuffaloy
88
Tuffaloy
77
Tuffaloy
55
Tuffaloy
77
Class 2 Alloy
Item No.
Tuffaloy
55
Class 3 Alloy
Item No.
Size Weight
In Pounds
Inches Per Foot
Weight
Pounds
Per Foot
Size
In
Inches
Class 1 Alloy Class 2 Alloy Class 3 Alloy
Item No.
Item No.
Item No.
1/8
3/16
1/4
5/16
3/8
1/2
9/16
5/8
.048
.106
.189
.296
.426
.758
.959
1.184
1.82
1.704
2.32
431-0125
431-0187
431-0250
431-0313
431-0375
431-0500
431-0562
431-0625
1/4 x 1/2
1/4 x 3/4
1/4 x 1
1/4 x 1-1/4
1/4 x 1-1/2
1/4 x 2
.484
.727
.96
1.20
1.44
1.92
434-0205
434-0207
434-0210
421-0187
421-0250
421-0313
421-0375
421-0500
421-0562
421-0622
421-0656
421-0748
421-0872
424-0210
424-0212
424-0215
424-0220
434-0215
434-0220
3/8 x 5/8
3/8 x 314
3/8 x 1
3/8 x 1-1/2
3/8 x 2
.900
1.08
1.44
2.16
2.88
434-0306
434-0307
434-0310
411-0625
424-0307
424-0310
424-0315
21/32
3/4
7/8
411-0750
411-0875
431-0750
431-0875
434-0320
1
3.03
3.84
4.74
5.74
6.82
7.97
9.28
421-1000
421-1125
421-1250
421-1375
421-1500
431-1000
431-1125
431-1240
431-1375
431-1500
431-1625
431-1750
1/2 x 3/4
1/2 x 1
1/2 x 1-1/4
1/2 x 1-1/2
1/2 x 2
1.44
1.92
2.40
2.138
3.134
4.133
5.81
424-0507
424-0510
434-0507
434-0510
434-0512
434-0515
434-0520
434-0525
434-0530
1-1/8
1-1/4
1-3/8
1-1/2
1-5/8
1-3/4
424-0515
424-0520
424-0525
424-0530
1/2 x 2-1/2
1/2 x 3
421-1750
421-2000
5/8 x 3/4
5/8 x 1
5/8 x 1-1/2
5/8 x 2
5/8 x 3
5/8 x 4
1.80
2.40
3.60
4.85
7.27
9.60
424-0607
424-0610
424-0615
424-0620
424-0630
424-0640
434-0607
434-0610
434-0615
434-0620
2
12.12
13.62
15.40
18.97
23.00
431-2000
431-2125
431-2250
431-2500
2-1/8
2-1/4
2-1/2
2-3/4
421-2250
421-2500
421-2750
3
27.15
32.05
37.18
421-3000
431-3000
431-3250
431-3500
3/4 x 1
3/4 x 1-1/4
3/4 x 1-1/2
3/4 x 2
3/4 x 2-1/4
3/4 x 2-1/2
3/4 x 3
2.88
3.64
4.32
5.72
6.48
7.20
8.64
424-0710
424-0712
424-0715
424-0720
434-0710
434-0712
434-0715
434-0720
434-0722
434-0725
3-1/4
3-1/2
3/8
5/8
3/4
7/8
.472
1.31
2.18
2.56
422-0375
422-0625
422-0750
422-0875
432-0750
432-0875
424-0725
424-0730
1
3.35
4.24
5.25
7.55
422-1000
422-1125
422-1250
422-1500
432-1000
432-1125
432-1250
432-1500
1 x 1-1/4
1 x 1-1/2
1 x 2
1 x 2-1/2
1 X 2-3/4
1 X 3
1-1/4 x 1-1/2
1-1/4 x 1-3/4
1-1/4 X 2
1-1/4 X 2-1/2
1-1/2 x 1-3/4
1-1/2 x 2
1-1/2 x 3
4.85
5.76
7.68
424-1012
424-1015
424-1020
424-1025
424-1027
424-1030
424-1215
424-1217
424-1220
424-1225
424-1517
424-1520
424-1530
434-1012
434-1015
434-1020
434-1025
1-1/8
1-1/4
1-1/2
9.70
10.56
11.55
7.25
8.40
9.60
12.06
10.09
11.60
17.28
1/4
3/8
1/2
5/8
3/4
.24
.54
.96
1.56
2.16
433-0250
433-0375
433-0500
433-0625
433-0750
434-1030
423-0500
423-0625
423-0750
1
3.84
6.00
8.64
423-1000
423-1250
423-1500
423-1750
433-1000
433-1250
433-1500
1-1/4
1-1/2
1-3/4
434-1520
434-1530
11.83
2 x 3-1/4
2 x 3-3/4
25.15
29.05
424-2032
424-2037
2
15.46
423-2000
433-2000
40
refractory metal compositions
TUFFALOY
Stronger, generally harder, and having less conductivity,
the refractory metal compositions include copper-tungsten
(Classes 10-11), tungsten (Class 13) and molybdenum
(Class 14) alloys.
COPPER TUNGSTEN RECTANGULAR
AND SQUARE BARS
Eight inches long, available in following dimensions:
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).
Widths from 1/8” to 2” and Thicknesses from 1/8” to 1”.
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 INSERTS
Available in following dimensions:
COPPER TUNGSTEN ROUND BARS
Diameters from 1/8” to 2” and Thicknesses
from 1/4” to 1”.
Eight inches long, available in the following diameters:
From 1/8” to 2”.
TUFFALOY
forgings
TUFFALOY 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
TUFFALOY 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.
41
TUFFALOY
shunts and jumpers
TYPE J
TYPE F
TYPE C
Laminated copper shunts a
to your size and shape spec
High conductivity electrolyt
strip is used, and terminal c
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
HOLE
PATTERN A
HOLE
PATTERN B
HOLE
PATTERN C
HOLE
PATTERN E
Air-cooled jumper cables are flexible,
high-conductivity copper conductors
with insulative sleeves. They are made
in lengths to suit your needs.
TERMINAL ORIENTATION
HOW TO ORDER
Give the following information:
Conductor rating (MCM)
Length between holes
Terminal orientation style
DIMENSIONS, INCHES
MCM
O.D. Lug Width Lug Thickness
Rating (approx.)
A
B
600
750
1000
1200
1500
1-5/8
1-3/4
2
2-1/8
2-1/4
1-3/8
1-3/8
1-1/2
1-1/2
1-1/2
.50
.60
.70
.82
.99
Holes are 17/32 unless otherwise specified.
42
accessories
TUFFALOY
TUFFCAP SOCKET REAMERS
To ream or dress sockets to hold male caps. 4 RW, Part No.
601-0014; 5 RW, Part No. 601-0015; 6 RW, Part No. 6010016.
TIP SOCKET REAMERS
Hole 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.
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.
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.
1
Tip File
RADIUS TIP FILE
To restore original contours of welding tips use this two-inch
radius file. Part No. 601-0120.
WELDING TIP EXTRACTORS
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, Part No. 601-0203
Large: EX-10-A, Part No. 601-0231
3/8” NPT hose plug
Part No. 601-0309
3/8” NPT hose socket
Part No. 601-0320
TUFFCAP EXTRACTORS
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
Male caps, 4 & 5 RW, EX-45, Part No. 601-0240
Male caps, 5 & 6 RW, EX-56, Part No. 601-0242
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.
43
TUFFALOY
weld force gauges
HIGH-ACCURACY WELD FORCE GAUGES AVAILABLE FROM TUFFALOY
Digital-Electronic
Digital-Hydraulic
Standard-Hydraulic
High-Capacity Hydraulic
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% accuracy. All are available in English and metric readouts.
Our Digital-Electronic gauge supplies
the highest accuracy (0.5% for 95%
of the gauges range). The gauge has
large LCD readouts with peak-hold
capabilities. All functions are electronic
which prevents variations caused
by flexing.
The Digital-Hydraulic delivers better
accuracy than standard hydraulic
gauges but at a lower price than all-
digital models. The peak-hold feature
allows for reading variable forces,
which are common in resistance
welding machinery. Gauges maintain
an accuracy of 1% for 30% to 90%
of the gauge’s range.
Tuffaloy’s Standard Hydraulic gauges
are the low cost method for obtaining
general force measurements. These
gauges are available in a standard
block style, with extensions. Sizes
range from 600 lb. up to 10 tons with
accuracy of 2% at the mean and 3%
outside of mean for 70% of the
gauge’s range.
44
weld force gauges
TUFFALOY
STANDARD GAUGE DATA
Maximum Increment Opening Extension
Item
Number
Description
Features
Reading
Every
Required
Length
Digital-Electronic
Weld Probe
• Analog output
• Auto shut-off
0-1000 lbs/
0-454 Kg
1 lb
1 Kg
601-8010MD
601-8045MD-KG
1/4”
1/2”
1.1”
1.1”
10”
10”
10”
10”
0-3000 lbs/
0-1133 Kg
1 lb
1 Kg
601-8300MD
601-8136MD-KG
• No-weld setting-
not required
0-5000 lbs/
0-2270 Kg
1 lb
1 Kg
601-8500MD
601-8227MD-KG
• Accuracy 0.5%
over full range
0-10,000 lbs/
0-2270 Kg
1 lb
1 Kg
601-8100MD
601-9453MD-KG
Digital-
Hydraulic*
• Accuracy 2%
0-1361 Kg
0-3000 lbs
0-5000 lbs
0-10,000 lbs
0-3000 lbs
1 Kg
1 lb
1 lb
1 lb
1 lb
3/4”
3/4”
3/4”
3/4”
3/4”
–
–
–
–
12”
601-1361D
601-3000D
601-5000D
601-9999D
601-3000D-12S
• NIST traceable
certification
Standard-
Hydraulic*
• Dual reading,
lbs and Kg
0-600 lbs
10 lb
20 lb
50 lb
50 lb
20 lb
20 lb
100 lb
50 lb
50 lb
100 lb
50 Kg
3/4”
3/4”
3/4”
3/4”
3/4”
3/4”
3/4”
3/4”
3/4”
3/4”
3/4”
–
–
–
12”
–
12”
–
–
18”
–
601-8006
601-8010
601-8020
601-8020-12
601-8030
601-8030-12
601-5000
601-6000
601-6000-18
601-8100
601-8101
0-1000 lbs
0-2000 lbs
0-2000 lbs
0-3000 lbs
0-3000 lbs
0-5000 lbs
0-6000 lbs
0-6000 lbs
0-10,000 lbs
0-5000 Kg
• Accuracy 3%
–
High-
Capacity
Hydraulic*
• Metric
equivalent
available
0-20,000 lbs
50 lb
1-3/4”
–
601-20000
* Hydraulic gauges should be selected to be used near mid-range.
45
TUFFALOY
welding data
RECOMMENDED USES OF RESISTANCE WELDING MATERIALS
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
BERYLLIUM-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
pressure 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
more readily machined and then subsequently heat treated.
GROUP B REFRACTORY METAL COMPOSITIONS
RWMA CLASS 10 • TUFFALOY 1W
TUNGSTEN 55% – COPPER 45%, suited for facings and inserts for projection welding electrodes and flash and butt welding electrodes.
It is recommended where (relatively) high electrical conductivity and some degree of malleability is desired.
RWMA CLASS 11 • TUFFALOY 10W
TUNGSTEN 75% – COPPER 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% – COPPER 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 CLASS 13 • TUFFALOY 100W (Pure Tungsten)
RWMA CLASS 14 • TUFFALOY 100M (Pure Molybdenum)
Class 13 & 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.
46
welding data
TUFFALOY
RWMA RECOMMENDED ELECTRODE MATERIALS FOR SPOT WELDING
Using Conventional Spot Welding Methods
TO WELD SIMILAR METALS
Tin
Terne
Plate
Galvanized Cadmium
Chrome
Plate
Stainless
Steel
18-8 Type
Scaly
H.R.
Steel
C.R. Steel
H.R. Steel
(Clean)
Ferrous
Plate
Iron Zinc
Plate
Plate
Steel
Steel
Steel
Steel
I
III
I
Read Block
Under Metal
To Be Welded
B
I
A
I
A
B
I
A
II
A
B
A
II
II
II
II
I
III
I
I
3
I
3
3
I
3
II
3
2
II
II
II
II
Nickel
Alloys
Silicon
Phosphor Bronze
Aluminum
Alloys
Brass
Cupro
Nickel
Nickel
Silver
Monel
Yellow
Bronze
Grade
Everdur
Olympic
Non-Ferrous Aluminum
Nickel
Dura-
Nichome 25-40%
(High
Res.)
luminum
Zinc
A, C & D Duronze
Herculoy
I
I
B
B
B
B
A
II
B
II
A
II
A
II
B
II
A
II
A
II
II
II
I
I
2
2
II
II
II
II
II
II
II
II
II
TO WELD DISSIMILAR METALS
Stainless Chrome Cadmium
Gal-
vanized
Iron
Terne
Plate
Steel
Tin
Plate
Steel
Ferrous
Alloys
LEGEND
BLOCK INTERPRETATION
Steel
Plate
Plate
Steel
18-8 Type Steel
II
I
Weld-
ability
Electrodes
Against
Special
Cold Rolled Steel
Hot Rolled Steel,
Clean
A
III
B
I
A
II
B
I
II
3
II
3
II
3
II
3
II
3
B
II
B
II
B
I
I
3
I
A
B
I
III
II
II
B
I
3
II
B
I
3
II
3
Electrodes
¬
Against Information
II
I
I
I
III
II
II
Tin Plate
Steel
3
3
I
3
WELDABILITY
A-Excellent
B-Good
B
I
II
B
I
B
I
B
I
II
Terne Plate
Steel
3
II
3
II
3
3
I
3
B
I
B
I
B
I
Galvanized Iron
Zinc Plate
ELECTRODES, RWMA Specifications
I = Group A, Class 1 - TUFFALOY 88
II = Group A, Class 2 - TUFFALOY 77 & TUFFALOY Z
III = Group A, Class 3 - TUFFALOY 55
Materials indicated in circles are second choice,
example II
3
B
I
B
I
Cadmium
Plate Steel
III
A
II
II
Chrome
Plate Steel
3
SPECIAL INFORMATION
1 - Special conditions required
2 - Good practice recommends cleaning before welding
3 - If plating is heavy, weld strength is questionable.
Non-Ferrous
Alloys
Nickel
Alloys
Phosphor Silicon
Bronze Bronze
Yellow
Brass
Nickel
Silver
Nickel
B
II
B
II
B
II
A
II
B
II
B
II
B
II
B
II
B
II
B
II
B
II
B
II
B
II
II
B
II
A
II
B
II
II
II
II
B
II
B
II
II
B
II
Cupro Nickel
II
Silicon Bronze
EverDur-Olympic
Bronze-Herculoy
II
II
II
II
II
II
II
Data based on Resistance Welding Equipment
Standards, Bulletin 16, a publication of the Resistance
Welder Manufacturers Association.
II
1
II
Nickel Silver
Nickel Alloys
1
II
Alum-
inum
I
B
II
II
Stainless Steel
18-8 Type
Aluminum Alloys
Duraluminum
III
II
I
2
1
II
III
II
47
TUFFALOY
welding data
MINIMUM PHYSICAL PROPERTIES FOR RWMA ALLOYS
Published Standards of the Resistance Welder Manufacturer’s Association
Proportional
Limit
Ultimate
Tensile
Strength
P. S. I.
Elongation
Percent
In 2’ or 4’
Diameter
TUFFALOY
Number
Hardness
Rockwell
Conductivity
Percent
I. A. C. S.
Class
Tension
P. S. I.
1
2
3
88
77
55
17,500
35,000
50,000
65-B
75-B
90-B
80
75
45
60,000
65,000
100,000
13
13
9
ROUND RODS
Up to 1” dia.
1
2
3
88
77
55
15,000
30,000
50,000
60-B
70-B
90-B
80
75
45
55,000
59,000
100,000
14
13
9
1” to 2” dia.
2” to 3” dia.
1
2
3
88
77
55
15,000
25,000
50,000
55-B
65-8
90-B
80
75
45
50,000
55,000
95,000
15
13
9
BARS
Square
Rectangular
Hexagon
1
2
3
88
77
55
20,000
35,000
50,000
55-B
70-B
90-B
80
75
45
60,000
65,000
100,000
13
13
9
Up to 1“ thick
GROUP A
Copper
Base
1
2
3
88
77
55
15,000
25,000
50,000
50-B
65-8
90-B
80
75
45
50,000
55,000
100,000
14
13
9
Over 1” thick
Alloys
1
2
3
88
77
55
20,000
22,000
50,000
55-8
65-B
90-B
80
75
45
45,000
55,000
94,000
12
13
9
FORGINGS
Up to 1”
1
2
3
88
77
55
15,000
21,000
50,000
50-B
65-B
90-B
80
75
45
40,000
55,000
94,000
13
13
9
1” to 2”
1
2
3
88
77
55
15,000
20,000
50,000
50-B
65-B
90-B
80
75
45
40,000
55,000
94,000
–
12
5
Over 2”
All sizes
4
44
85,000
33-C
20
140,000
.5
2
3
4
5
77
55
44
66
20,000
45,000
60,000
55-8
90-B
33-C
70
45
18
45,000
85,000
90,000
12
5
.5
CASTINGS
All sizes
12 to 16,000 65 to 85-B
10 to 15
65 to 75,000
2 to 10
10
11
12
13
14
1W
10W
20W
100W
100M
72-B
94-B
98-B
69-A
85-B
35
28
27
30
30
GROUP B
Refractory
Metal
135,000
160,000
170,000
Ultimate
Compression
Strength
Rods,
Bars &
Inserts
}
200,000
P. S. I.
Compositions
48
helpful suggestions
TUFFALOY
Thickness Electrode
Net
Weld
Time
Welding
Current
Mini-
mum
Con-
tacting Spacing
Over-
lap
Mini-
mum
Weld
Dia-
meter
of
Fused
Zone
Thickness
SPOT WELDING LOW CARBON STEEL
1. Type of steel: SAE 1010
“T” of
Thinnest
Outside
Piece
Diameter Elec-
Minimum Shear
Strength
“T” of
Thinnest
Piece
trode (Single (Approx.)
Force
Im-
pulse)
2. Material should be free from scale, oxides, paint, grease and oil.
Lbs.
3. Welding conditions determined by Thickness “T” of thinnest
outside piece.
Tensile
Tensile
Strength Strength
Cycles
(60
Per
Below
70000
PSI
70000
PSI
And
4. Data for total thickness of pile-up not exceeding 4 “T”.
Recommended maximum ratio between two thicknesses: 3 to 1.
In.
Approx.
Inches
Inches
Lbs.
Sec.)
Amps
Inches
Inches
Above
Inches
5. Electrode Material: Class 2 (Tuffaloy 77)
0.010
0.021
0.031
0.040
0.050
0.062
0,078
0.094
0.109
0.125
3/8
3/8
3/8
1/2
1/2
1/2
5/8
5/8
5/8
7/8
200
300
400
500
650
4
6
8
10
12
14
17
20
25
26
4000
6500
6600
9500
10500
12000
14000 11/16 1-1/4
15500 3/4 1-1/2
17500 15/16 1-5/8
3/8
7/16
7/16
1/2
9/16
5/8
1/4
3/8
1/2
3/4
7/8
1
0.10
0.13
0.16
0.19
0.22
0.25
0.29
0.31
0.32
0.33
130
320
570
180
440
800
1200
–
–
–
–
–
–
0.010
0.021
0.031
0.040
0.050
0.062
0.078
0.094
0.109
0.125
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.
920
1350
1850
2700
3450
4150
5000
800
1100
1300
1600
1800
18000
7/8
1-3/4
Thickness
(of thinnest
piece)
Electrode
Diameter
Net
Electrode
Force
WeId
Time
Welding
Current
(Approx.)
Minimum
Overlap
SPOT WELDING GALVANIZED STEEL
1. Type of galvanized: 1.25 oz/ft2 nominal.
Inches
Inches
Pounds
Cycles
Amps.
Inches
2. Material should be free from dirt, paint, grease and oil.
0.030
0.035
0.040
0.050
0.060
0.075
0.093
0.109
1/2
1/2
5/8
5/8
5/8
3/4
3/4
3/4
475
550
625
11
12
13
18
23
28
34
39
10,500
11,000
12,500
14,000
15,500
19,500
24,000
28,500
1/2
9/6
5/8
11/16
3/4
7/8
3. Welding conditions determined by thinnest of two pieces only.
Schedule is good for thickness ratios up to 2:1.
840
1050
1400
1800
2200
4. Electrode material: Class 1 or 2 (Tuffaloy 88 or 77).
5. Electrode nose design: Dome or truncated cone.
(from International Lead, Zinc Research Organization, Inc.)
1
1-1/4
Thickness “T”
of Thinnest
Outside Piece Projection
Diameter Height of
Minimum Shear Strength
(Single Projecting Only)
Diameter
of Fused
Zone
Minimum
(At Weld
Interface
Minimum
Contacting
Overlap
“L”
PROJECTION WELDING DATA FOR LOW
CARBON AND STAINLESS STEEL
of
Projection
“H”
(Nominal)
“D”
Pounds
1. TYPES OF STEEL:
Tensile
Tensile
Strength
70000
Up To
150000
PSI
Tensile
Low-Carbon-SAE 1010
Stainless-Types 309, 310, 316, 317, 321, 347 and 349.
(Non-Hardenable: Max. Carbon content 0.15%)
Strength
Below
70000
PSI
Strength
150000
PSI
And
Above
Inches
Inches
Inches
Inches
Inches
2. Material should be free from scale, oxides, paint, grease and oil.
0.010
0.012
0.014
0.016
0.021
0.025
0.031
0.034
0.044
0.050
0.062
0.070
0.078
0.094
0.109
0.125
0.140
0.156
0.171
0,187
0.203
0.250
0.055
0.055
0.055
0.067
0.067
0.081
0.094
0.094
0.119
0.119
0.156
0.156
0.187
0.218
0.250
0.281
0.312
0.343
0.375
0.406
0.437
0.531
0.015
0.015
0.015
0,017
0.017
0.020
0.022
0.022
0.028
0.028
0.035
0.035
0.041
0.048
0,054
0.060
0.066
0.072
0,078
0.085
0,091
0.110
130
170
200
240
320
450
635
790
920
1350
1950
2300
2700
3450
4150
4800
6000
7500
8500
10000
12000
15000
180
220
280
330
440
600
850
1000
1300
1700
2250
2800
3200
4000
5000
5700
–
250
330
380
450
600
820
1100
1300
2000
2400
3400
4200
4800
6100
7000
8000
–
0.112
0.112
0.11 2
0.112
0.140
0.140
0.169
0.169
0.169
0.225
0.225
0.281
0.281
0.281
0.338
0.338
7/16
1/8
1/8
1/8
3. Size of projection normally determined by thickness of thinner
piece, and projection should be on thicker piece where possible.
5/32
5/32
3/16
7/32
7/32
9/32
9/32
3/8
3/8
7/16
1/2
5/8
11/16
3/4
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. Projection should be made on piece of higher conductivity when
dissimilar metals are welded.
8. For diameter of projection “D” a 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.
–
–
–
–
–
–
–
–
1/2
9/16
9/16
5/8
13/16
7/8
15/16
1
9. For height of projection “H” a 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.
–
–
11/16
1-1/4
PROJECTION WELDING SCHEDULE GUIDE
FOR ONE PROJECTION:
CURRENT = 1T + .045 x 100,000 AMPS
FOR MORE THAN ONE PROJECTION:
CURRENT = 1T + .045 x 100,000 + 30% FOR EACH ADDITIONAL PROJECTION
TIME
= 2T x 100 HERTZ (CYCLES)
= 2T x 6,000 LBS.
TIME
= 2T x 100 HERTZ (CYCLES)
PRESSURE = 2T x 6,000 + 50% FOR EACH ADDITIONAL PROJECTION
49
TUFFALOY
helpful suggestions
Many factors affecting electrode cost and useful electrode life
are briefly outlined below.
The RWMA tip numbering system has generally replaced the
old Morse taper numbers with new “RW” numbers, and has
added two new sizes, as the chart illustrates.
PART TO BE WELDED
Lay out the part for resistance welding. Designing engineer,
welding engineer and production man in charge of welding
should 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
approach 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 even handling marks have a decided effect on weld quality.
Cleaning may have to be a part of the welding job in some cases.
ELECTRODE LIFE SAVERS
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.
WELDING EQUIPMENT AND CONTROL
A welding machine of reputable quality purchased for a
particular application will be correctly designed both electrically
and mechanically, and will be supplied the correct control
equipment and electrodes for the work.
2. Use ample cold cooling water as close as practical
to the welding contact surface, properly circulated
at a minimum of 30-psi pressure, and supplied at a
rate of at least 1-1/2 gallons per minute.
On machine change-overs make sure of adequate electrical
and mechanical capacity, and see that the necessary controls
are provided. Consult us when redesigning or revising your
choice of electrodes.
3. Be sure to select the proper type and size of
electrode, taking into consideration electrode
pressure, contact area of electrode, gauge, and
nature 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.
STANDARD GAGE CHART
Thickness in Decimals of an Inch
Gage Manufacturer’s Gage Manufacturer’s Gage Manufacturer’s
No.
Standard
No.
Standard
No.
Standard
3
4
5
6
7
8
9
10
11
0.2391
0.2242
0.2092
0.1943
0.1793
0.1644
0.1495
0.1345
0.1196
12
13
14
15
16
17
18
19
20
21
0.1046
0.0897
0.0747
0.0673
0.0598
0,0538
0.0478
0.0418
0.0359
0.0329
22
23
24
25
26
27
28
29
30
0.0299
0.0269
0.0239
0.0209
0.0179
0.0164
0.0149
0.0135
0.0120
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.
* Resistance Welding Manual, published by the Resistance Welder
Manufacturers Association.
RESISTANCE WELDING MACHINE SETUP
TO DETERMINE SPOT WELDING SCHEDULE
APPROXIMATE PRESSURE EXERTED BY AIR CYLINDER SIZE
DIAMETER CYLINDER AREA
SQ. INCHES
CURRENT
TIME
=
=
=
2T x 100,000
2T x 100
=
=
=
AMPERES
CYCLES
4”
5”
6”
8”
=
=
=
=
12.5
19.5
28.0
50.0
x
x
x
x
=
=
=
=
WELDER
GUAGE
PRESSURE
ELECTRODE
FORCE
PRESSURE
PRESSURE
2T x 6000 (LB)
FORCE REQUIRED (LB)
T = THICKNESS OF THE THINNEST PIECE
50
helpful suggestions
TUFFALOY
RESISTANCE WELDING
PROBLEM SOLVING
EXPULSION AT WELD INTERFACE
LOW WELD STRENGTH
• Short Weld Time
• Low Weld Force
DISPLACED WELD NUGGET
• Electrode Misalignment
• Poor Heat Balance
• Poor Fit Up
• Short Squeeze Time
• Low Weld Force
• Dirty – Scaly Material
• Poor Fit Up
• Low Weld Current
• Small Electrode Face Area
• Poor Heat Balance
• Welds Too Close Together
CRACKS IN PARENT MATERIAL
• Insufficient Edge Distance
• High Weld Force
SURFACE EXPULSION/
ELECTRODE STICKING
• Insufficient Cooling
• Metallurgy of Material Welded
EXCESSIVE WELD INDENTATION
• Long Weld Time
• High Weld Force
• High Weld Current
• Poor Fit Up
• Welder Head Impacts Work
• Short Squeeze Time
• Long Weld Time
• Short Hold Time
• Low Weld Force
• High Weld Current
• Dirty – Scaly Material
INTERNAL CRACKS IN WELD NUGGET
• Short Hold Time
• Low Weld Force
• Dirty – Scaly Material
• Metallurgy of Material Welded
• Poor Head Follow Up
ELECTRODE MUSHROOMING
• Insufficient Cooling
• Low weld Force
• High Weld Current
• Small Electrode Face Area
• Long Weld Time
• Welder Head Impacts Work
HELPFUL HINTS
• 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.
are not possible with this manual method.
• If the use of a hammer is necessary on resistance
welding machine or its components, use rubber,
plastic, brass, raw-hide or other soft material. Never
use a steel hammer.
• 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 electrode.
• 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.
• Confirm there is water flow from the electrodes,
transformer, control and other cooled components
before welding.
• Perform maintenance to Resistance Welding equipment
as outlined in RWMA Bulletin 14.
• Always use the proper size water hose, if removed check
for obstructions that might impede flow.
• Keep in mind that sparks/expulsion are 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
desired settings. Expulsion can be dangerous and
could also result in questionable product.
• When a set up will not be used for a period of time remove
the electrodes from the holders to avoid freezing into the
holder due to corrosion.
• Use fine emery cloth to dress 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
51
TUFFALOY
helpful suggestions
RESISTANCE WELDING
DO’S
DON’TS
• Use the RWMA recommended electrode material for the
job you are running.
• Never use unidentified electrodes or materials.
• Avoid special, offset, or irregular electrodes when the
job can be done with standard electrodes.
• Use RWMA standard electrodes whenever possible.
• Use the appropriate electrode diameter for the material
being welded.
• Do not use small electrodes on heavy gauge welding
jobs or large electrodes on small gauge materials.
• Use open sight drains or have water flow gauges on out
bound side to easily confirm water flow.
• Do not forget to turn the water on full force before
starting to weld.
• Connect the water inlet hose to the proper holder inlet to
insure water flows through the center cooling tube first.
• Never use water hoses that do not fit the water fitting
properly.
• Recommended water flow for the electrodes is 1.5 gallons
per minute of cold water.
• Do not allow water connections to become leaky,
clogged or broken.
• Insure that the water tube extends within 0.25” of the
bottom of the electrode water hole.
• Avoid holders with leaking or deformed tapers.
• Never use holders that do not have adjustable water
deflector tubes.
• Adjust the water tube position when changing to another
length electrode.
• 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.
• Check water tube ends to insure they are not
damaged and have an angled cut at the end to prevent
water restriction.
• Use ejector type holders to simplify electrode removal.
• Do not use a steel hammer to adjust any part of a
welding machine.
• Keep the electrode and holder tapers clean to ensure
good leak free conduction.
• Do not permit seam welding wheels to run off the edge
of the work piece.
• Dress electrodes frequently to insure good quality welds.
• Use raw-hide or hard rubber hammers for alignment
of electrodes.
• Do not enter a work cell or reach into a welder without
using your lockout.
• 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.
52
Tuffaloy Products, Inc. – Greer, South Carolina, USA
RWMA
MEMBER
TUFFALOY PRODUCTS, INC.
1400 South Batesville • Greer, South Carolina 29650
Tel: (800) 521-3722
• (864) 879-0763 • Fax: (864) 877-2212
Visit our Web Site at: www.tuffaloy.com
ISO 9001:2000
Certificate No.:
QEC15642
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
it’s 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 Tuffaloy’s option, repair or replace the nonconforming product, F.O.B. Tuffaloy’s 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.
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