Abstract: A welding contact tip or a weld nozzle is provided with a coating comprising a film of tungsten disulfide or other low friction material. The film provides resistance to weld spatter without interrupting electrical contact between the contact tip and electrode wire.

Abstract: Aluminum weld wire having a nascent aluminum surface, (the weld wire is also useful for vacuum and arc metallizing), is lubricated with a dual coating of an essentially anhydrous lower alkanol and a colloidal solid lubricant each present as a layer so thin that they are essentially invisible to the naked eye. The solid lubricant is oil-free colloidal graphite which may be combined with a minor amount of a sulfide of molybdenum. The lubricant particles are deposited from a 1% to 15% by wt dispersion of the particles in the alkanol, in substantially spaced-apart relation, forming a non-uniform, monoparticulate layer on the nascent aluminum surface. The high propensity of the lubricant particles to settle out (they are smaller than 10 microns, and generally smaller than 1 micron in size) from the dispersion, permits formation of the monoparticulate layer. The alkanol layer is so thin that only from 100 ppm to 0.1% of alkanol, by weight of the weld wire, is present.

Abstract: Metal articles are press-fitted together, using a lubricant dispersion comprising about 1-15 wt % colloidal graphite in isopropanol. The isopropanol is removed and the articles are then welded together at a joint to form a unitary weldment. The process is especially suitable for use on articles made from aluminum and aluminum alloys.