How to deal with the phenomenon of wear on the spot welding head

Following the deformation and wear of the electrode tip, the area of the spot welding head will increase, and the strength of the solder joint will be lost. In order to ensure the size of the nugget and the strength of the solder joint, the welding time and welding current can be mutually compensated within a certain range. In order to obtain a certain strength of the solder joints, high current and short time （strong premise, also called hard specification）can be used, or small current and long time（weak premise, also called soft specification）. The choice of hard specifications for spot welding heads or soft specification depends on the function, thickness of the metal and the power of the welding machine used. There is an upper limit for the current and time required to withstand the metal of incompatible function and thickness, and the duration shall prevail.

The electrode pressure of the spot welding head has a significant effect on the total resistance R between the two electrodes. As the electrode pressure increase, R decreases significantly, but the increase in welding current does not fluctuate greatly, and does not affect the heat generation of R. The strength of the spot welding always decreases as the welding pressure increases. The solution is to increase the welding current while increasing the welding pressure. For spot welding heads, the area of the electrode determines the current density, and the resistivity and thermal conductivity of the electrode material are related to the generation and loss of heat. The shape and material of the electrode have a significant impact on the formation of the nugget.

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