TUFFALOY WELDING DATA

RECOMMENDED USES OF RESISTANCE WELDING MATERIALS

GROUP A COPPER-BASE ALLOYS
RWMA Class 1 alloy TUFFALOY 88
CADMIUM-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's used for welding electrodes, projection welding dies, seam welding shafts and bearings, flash and butt welding dies, 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
NICKEL-COPPER (55) and BERYLLIUM-NICKEL-COPPER (55A) are suited to welding steels having high electrical resistance, such as stainless steel.

Class 3 alloy is recommended for projection welding dies, and flash and butt welding dies. 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 dies. 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, die 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 dies. 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 dies. 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 die facings, and for electrode facings used to upset studs and rivets. A material for heavy-duty projection welding electrodes and dies.

RWMA Class 13 TUFFALOY 100W
TUNGSTEN

RWMA Class 14 TUFFALOY 100M
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,

R.W.M.A. RECOMMENDED ELECTRODE MATERIALS FOR SPOT WELDING

Using Conventional Spot Welding Methods

LEGEND
Block Interpretation

WELDABILITY ELECTRODES AGAINST

ELECTRODES AGAINST SPECIAL INFORMATION

WELDABILITY

A- Excellent

B- Good

ELECTRODES, R.W.M.A. 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 squares are second choice, example

II

SPECIAL INFORMATION

1- Special conditions required

2 - Good practice recommends cleaning before welding

3 - If plating is heavy, we strength is questionable.

Data based on Resistance Welding Equipment Standards, Bulletin 16, a publication of the Resistance Welder Manufacturers Association.

TO WELD SIMILAR METALS

FERROUS Tin Plate Steel Terne Plate Steel Galvanized Iron     Zinc Plate           Cadmium Plate Steel     Chrome Plate Steel                   Stainless Steel      18-8 Type    Scaly H.R.     Steel     C.R. Steel H.R. Steel (clean)

READ BLOCK UNDER METAL TO BE WELDED B I A I A I

II

B I A II A III

II

B I
  II
A II

I 3 I 3 I

II

3 I 3 II 3 III

II

I
  II
2 II

NON-FERROUS Aluminum Aluminum Alloys Duraluminum Cupro Nickel Nickel Silver Nickel Nickel Alloy Monel Nichome (High Res) Brass Yellow 25-40% Zinc Phosphor Bronze Grade A, C & D Silicon Bronze Everdur Olympic Duronze Herculoy

B I

II

B I

II

A II B II A II A II B II AB II AB II

I

II

2 I

II

2 II II II II II II II

TO WELD DISSIMILAR METALS

FERROUS ALLOYS Stainless Steel 18-8 Type Chrome Plate Steel Cadmium Plate Steel Galvanized Iron Zinc Plate     Terne Plate   Steel     Tin Plate     Steel

  Cold Rolled Steel Hot Rolled Steel, Clean A II

III

A II B II B I A I

II

B I

III II 3 II 3 II 3 II 3 II 3

Tin Plate Steel B II

III

B II B I

II

B I B I

II

I I 3 I 3 I 3 I 3

Terne Plate Steel   B II B II B I

II

B I

I 3 I 3 I 3 I 3

Galvanized Iron   Zinc Plate B II B II B I

I 3 I 3 I 3

Cadmium Plate Steel B II B II

I 3 I 3

Chrome Plate Steel A III

II

II 3

NON-FERROUS ALLOYS Nickel Alloys Nickel Phosphor Broze Silicon Bronze Yellow Brass Nickel Silver

Cupro Nickel B II B II B II B II B II B II

II II II II II II

Silicon Bronze Everdur – Olympic Bronze – Herculoy B II B II B II A II B II

II II II II II

Nickel Silver B II B II B II B II

II 1 II II 1 II

Nickel Alloys A II B II

ALUMINUM

ALUMINUM ALLOYS DURALUMINUM B I

II

I

II

2

II II

Stainless Steel 8-8 Type B II B II

III

II

1 II

III

3

MINIMUM PHYSICAL PROPERTIES FOR R.W.M.A. ALLOYS

Published Standards of the Resistance Welder Manufacturers Association

GROUP A Copper Base Alloys CLASS TUFFALOY   NUMBER PROPORTIONAL LIMIT TENSION P.S.I. HARDNESS ROCKWELL CONDUCTIVITY PER CENT I.A.C.S. ULTIMATE TENSILE STRENGTH P.S.I. ELONGATION % IN 2" OR 4"DIAMETER

  ROUND RODS
Up to 1" diameter
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

  1" to 2" diameter 1
2

3
88
77

55
15,000
30,000

50,000
55-B
65-B

90-B
80
75

45
50,000
55,000

95,000
14
13

9

  2" to 3" diameter 1
2

3
88
77

55
15,000
25,000

50,000
55-B
70-B

90-B
80
75

45
50,000
55,000

95,000
15
13

9

BARS Square Rectangular Hexagon Up to 1" thick 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

  Over 1" thick 1
2

3
88
77

55
15,000
25,000

50,000
50-B
65-B

90-B
80
75

45
50,000
55,000

100,000
14
13

9

FORGINGS Up to 1" 1
2

3
88
77

55
20,000
22,000

50,000
55-B
65-B

90-B
80
75

45
45,000
55,000

94,000
12
13

9

1" to 2" 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

  Over 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

  All sizes 4 44 85,000 33-C 20 140,000 .5

CASTINGS All sizes 2
3

4

5
77
55

44

66
20,000
45,000

60,000

12 to 16,000
55-B
90-B

33-C

65 to 85-B
70
45

18

10 to 15
45,000
85,000

90,000

65 to 75,000
12
5

.5

2 to 10

GROUP B Refractory Metal Compositions Rods, Bars & Inserts 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
135,000
160,000

170,000

200,000

200,000
Ultimate Compression Strength P.S.I.

WELDABILITY	ELECTRODES AGAINST
ELECTRODES AGAINST	SPECIAL INFORMATION