Abstract: A connecting adapter configured to mate on opposite ends with a standard adapter shank and a standard welding electrode of the resistance type. The connecting adapter is a hollow body with male and female connecting portions. The male portion, integral with the female portion, is sized to accommodate the standard welding electrode thereon. The female portion is sized to accommodate a taper portion of the shank within the hollow body and has exterior cross-sectional dimensions similar to those of the shank. The connecting adapter being formed of a wear-resistant conductive martial is replaced only periodically, thus reducing greatly the wear on the more expensive standard adapter shank.

Abstract: A process is provided for forming a resistance welding electrode. The process includes the step of providing a billet formed from a high conductivity metal. The billet includes a first portion having a first inner cavity formed therein. The process further includes the steps of inserting an insert into the first inner cavity of the billet, and deforming the insert so as to mechanically lock the insert in place in the billet. The deformed billet comprises the resistance welding electrode.

Abstract: A process is provided for forming a resistance welding electrode. The process includes the step of providing a billet formed from a high conductivity metal. The billet includes a first portion having a first inner cavity formed therein. The process further includes the steps of inserting an insert into the first inner cavity of the billet, and deforming the insert so as to mechanically lock the insert in place in the billet. The deformed billet comprises the resistance welding electrode.

Abstract: A process is provided for forming a resistance welding electrode. The process includes the step of providing a billet formed from a high conductivity metal. The billet includes a first portion having a first inner cavity formed therein. The process further includes the steps of inserting a dispersion strengthened copper insert into the first inner cavity of the billet thereby forming an insert-containing billet, and deforming the insert-containing billet so as to mechanically lock the insert in place in the billet. The deformed insert-containing billet comprises the resistance welding electrode.