Abstract: A method for manufacturing a spark plug which reduces the generation of spatters and the possibility of insufficient weld strength resulting from penetration depth insufficiency of a weld metal portion is disclosed. In accordance with the method, a chip joint face formation portion of a center electrode is formed from a heat-resistant alloy predominantly containing Fe or Ni. A noble metal chip is attached to a chip joint face of the chip joint face formation portion to thereby form a chip-attached assembly. A full-circled laser-beam weld metal portion is formed on the chip-attached assembly in such a manner as to intrude into the noble metal chip and into the chip joint face formation portion. A graded-index-type fiber optic cable is used as an optical transmission path extending between a laser beam generator and an optical emission section. A laser beam which is transmitted from the laser beam generator through the cable irradiates the chip-attached assembly while being condensed.

Abstract: A method for manufacturing a spark plug which reduces the generation of spatters and the possibility of insufficient weld strength resulting from penetration depth insufficiency of a weld metal portion is disclosed. In accordance with the method, a chip joint face formation portion of a center electrode is formed from a heat-resistant alloy predominantly containing Fe or Ni. A noble metal chip is attached to a chip joint face of the chip joint face formation portion to thereby form a chip-attached assembly. A full-circled laser-beam weld metal portion is formed on the chip-attached assembly in such a manner as to intrude into the noble metal chip and into the chip joint face formation portion. A graded-index-type fiber optic cable is used as an optical transmission path extending between a laser beam generator and an optical emission section. A laser beam which is transmitted from the laser beam generator through the cable irradiates the chip-attached assembly while being condensed.

Abstract: A method for manufacturing a spark plug having a center electrode, an insulator disposed around the center electrode, a metallic shell disposed around the insulator, a ground electrode disposed in opposition to the center electrode so as to form a spark discharge gap therebetween, and a chip of a high melting point metal welded to at least the ground electrode. A zinc-based plating layer is formed on the surface of a metallic shell assembly composed of the metallic shell and the ground electrode, a root-end of which is welded to the metallic shell. Subsequently, the zinc-based plating layer is removed from a free-end portion of the ground electrode. The chip of a high melting point metal is welded to the free-end portion of the ground electrode from which the zinc-based plating layer has been removed.

Abstract: In a spark plug, a cylindrical metal shell is provided whose inner wall has a ledge portion on which an insulator rests through its seat portion. The insulator has an axial bore in which a center electrode is placed whose front end has a heat-resistant metal tip. A ground electrode is provided to form a spark gap with the noble metal tip of the center electrode. The insulator forms an insulator nose which measures less than 15 mm in length. The heat-resistant metal tip measures less than 0.8 mm in diameter. A space between an outer surface of the center electrode and an inner wall of a front open end of the axial bore is defined to be more than 0.1 mm in width.

Abstract: In a center electrode structure for spark plug including a tubular insulator, the inner side of which has a stepped shoulder to provide a diameter-reduced bore therein; a center electrode having a flange, and concentrically placed into the insulator with the flange engaging against the shoulder, and with one end being axially through the bore so as to be exposed to outside of the insulator; the center electrode having a highly heat conductive core of copper or copper-based alloy which is encased into an enclosure made of oxidation and heat resistant nickel-based alloy; and the core providing its overall outer surface with a thin oxidation layer, so that the core is clad with the enclosure through the oxidation layer by means of extrusion.

Abstract: In a center electrode structure for spark plug including a tublar insulator, the inner side of which has a stepped shoulder to provide a diameter-reduced bore therein; a center electrode having a flange, and concentrically placed into the insulator with the flange engaging against the shoulder, and with one end being axially through the bore so as to be exposed to outside of the insulator; the center electrode having an electrically conductive core of copper or copper-based alloy which is encased into an enclosure made of oxidation and heat resistant nickel-based alloy; and the core being provided with a number of fractures in its granular structure so as to absorb thermal stress due to the thermal expansional difference between the core and enclosure.