Abstract: A system and method apparatus for purging liquid coolant from liquid coolant lines providing cooling to welding electrodes in a welding apparatus. The system provides a purging fluid of air at a pressure higher than a pressure of the liquid coolant to be purged. High-pressure air is generated by a centralized compressor and distribution system, a local electric pump, or existing robotic arm movements applied to pump bellows mounted thereon. A variety of placements, tie-ins, and hardware for fluid purging line(s) and its valve(s), for coolant supply(ies) and its valve(s), for coolant return(s) and its valve(s), and for liquid coolant line(s) and its valve(s) allow individual liquid coolant lines to be purged independently, with trade-offs of speed to purge, thoroughness of purge, amount of liquid coolant needed to be purged.

Abstract: A removal device of a welding electrode tip includes a first insertion piece and a second insertion piece that are inserted into a space formed between an end surface of a large diameter portion of a shank and an end surface of the welding electrode tip, each of the first insertion piece and the second insertion piece having a wedge shape having a thickness that increases from a front end to a back portion in an insertion direction, wherein the first insertion piece and the second insertion piece have a thickness by overlap of the first insertion piece and the second insertion piece, and the thickness changes from a thickness smaller than a length of the space to a thickness larger than the length of the space according to an overlap amount in the space.

Abstract: The invention provides a thin film deposition system and a method, and relates to the field of thin film deposition. The deposition method comprises the following steps: 1) heating metal substrate; carrying out deposition. The method is characterized in the step 1) that a current is conducted into the metal substrate at one end of the growth zone by one electrode, and out of the metal substrate at the other end of the growth zone by the other electrode, so that the metal substrate is heated by the heat emitting of the resistant of the metal substrate itself. According to the method, the quality of the prepared thin film is improved, while the preparation cost of the thin film is reduced. In addition, the consistent double-sided thin films can be easily prepared on two surfaces of the metal substrate by employing the system and method.

Abstract: An apparatus includes a housing, a pin, a mechanism and a sensor. The housing is configured to receive a weld head. The pin is configured to move linearly relative to said housing. The mechanism is configured to convert a position of said pin into a displacement. The sensor is configured to generate a value representative of said position of said pin based on said displacement.

Abstract: The present disclosure is directed to a method for tuning the performance of at least one electrochemical cell of an electrochemical cell stack. The method includes supplying power to an electrochemical cell stack. The electrochemical cell stack includes a plurality of electrochemical cells. The method further includes monitoring a parameter of at least one electrochemical cell and determining if an electrochemical cell becomes impaired. The method also includes diverting a fraction of the current flow from the impaired electrochemical cell during operation of the electrochemical cell stack.

Abstract: The present invention provides a spot resistance welding electrode cap for welding two or more work-pieces together, including a substantially cylindrical body having an interior surface, an exterior surface, and a tapered interior cavity for frictionally fitting over an electrode shank. The exterior surface of the body includes a plurality of longitudinally extending depressions or flutes formed therein which provide an increased external surface area to the electrode cap, thus increasing the ability to transfer additional amounts of heat. The electrode cap further includes a plurality of fins disposed on the interior surface of the body within the interior cavity. The free ends of the fins are chamfered in order to ease the transition of coolant flowing throughout the shank proximate the electrode cap.

Abstract: The invention provides a thin film deposition system and a method, and relates to the field of thin film deposition. The deposition method comprises the following steps: 1) heating metal substrate; carrying out deposition. The method is characterized in the step 1) that a current is conducted into the metal substrate at one end of the growth zone by one electrode, and out of the metal substrate at the other end of the growth zone by the other electrode, so that the metal substrate is heated by the heat emitting of the resistant of the metal substrate itself. According to the method, the quality of the prepared thin film is improved, while the preparation cost of the thin film is reduced. In addition, the consistent double-sided thin films can be easily prepared on two surfaces of the metal substrate by employing the system and method.

Abstract: A torch extender for a plasma arc cutting system is provided. The plasma torch extender includes an elongated substantially dielectric body that defines a first end and a second end and includes a flexible section that is poseable across a plurality of orientations. The torch extender also includes a first connector, at the first end of the elongated substantially dielectric body, which mates with a consumable set, and a second connector, at the second end of the elongated substantially dielectric body, which mates with a torch mount. The torch extender further includes a consumable detection medium that communicates the presence of the consumable set. The consumable detection medium is disposed within the elongated substantially dielectric body and extends between the first end and the second end of the elongated substantially dielectric body.

Abstract: A projection welding gun device includes an upper welding tip and a lower welding tip that are combined with a gun body through a shank, where the upper welding tip presses an upper panel corresponding to a protrusion portion that is formed on a lower panel to weld the upper and lower panels, and a rotation unit that is rotated by a driving portion is disposed between the gun body and the shank to rotate the shank.

Abstract: A resistance welding electrode includes a shaft-shaped holder and an electrode part in the form of an electrode cap or a pin electrode which are non-positively connected via tapered surfaces. Furthermore, cooling bores are also present. In such a resistance welding electrode the tapered cone angle is in a region of about 1 degree to 3 degrees and the holder and the electrode part are connected such that the holder and the electrode part are further in axial contact with each other via a radial surface contact, and the edge of the electrode part facing the holder is restrained in an associated reception recess on the holder side by means of reduction.

Abstract: In some aspects, multi-metallic emissive inserts shaped to be disposed within an electrode for a plasma arc torch electrode can include an exposed emitter surface at a distal end of the emissive insert to emit a plasma arc from the electrode, wherein the emissive insert comprises a first emissive material and about 8 weight percent to about 50 weight percent yttrium.

Abstract: The invention relates to a hydraulic expansion chuck having an end on the tool side; and an end on the machine side. A shaft is disposed on the end on the machine side for clamping the expansion chuck in a machine tool. An expanding bushing is disposed on the end on the tool side and surrounded by a pressure chamber and can be radially deformed for clamping a tool under the action of a pressure medium received in the pressure chamber.

Abstract: An apparatus for resistance welding with a welder includes a heat pipe including a hollow tube and a weld electrode fitted around a portion of the heat pipe. The weld electrode and heat pipe are conductively coupled to conduct heat across an inner surface of the weld electrode.

Abstract: A welding assembly including a current generator, a first electrode electrically coupled to the current generator, the first electrode including a first engagement surface, and a second electrode electrically coupled to the current generator, the second electrode including a second engagement surface and defining a recess in the second engagement surface.

Abstract: A cold-formed electrode tip for use in spot welding is provided. The cold-formed electrode tip includes a base, a rounded face, and an annular wall extending along a longitudinal axis of the electrode tip, the annular wall having a thickness such that the annular wall is configured to be readily deformed by a handheld tool.

Abstract: In an earth electrode apparatus, a cradle having first, second, and third shanks to which first, second, and third earth electrodes can be attached respectively is coupled to a shaft supported by a base. The cradle is coupled thereto in a tiltable manner. If the surface of a workpiece is irregular or inclined, the cradle tilts for balancing with the workpiece to ensure equal contact pressure for the contact of the first, second, and third earth electrodes with the workpiece, thereby offering stable contact irrespective of surface irregularity or inclination. Since a welding current is split to flow into the first, second, and third earth electrodes through respective points of contact thereof with the workpiece, it is possible to reduce current density at each of the points of contact and to avoid heat generation ascribable to conductive resistance at each of the points of contact.

Abstract: A device for cooling welding caps of a welding apparatus includes a cooling line (10). A cooling agent is kept under pressure during removal of the welding caps. An expansion device (16) including an expansion chamber (34) is connected to the cooling line (10).

Abstract: A welding electrode has a body having a shank and a contact region for placement against a workpiece during welding. A portion of the body may be formed on a parabolic profile. A coating is formed on the contact region. The coating may have a first layer, and a second layer formed over the first layer. The first and second layers may have different compositions. The electrode may have internally formed cooling finwork for interaction with a liquid cooling system.

Abstract: An improved spot welding tip is adapted for welding a set of adjacent members within a heated zone during a welding program, wherein a quantity of energy is produced, and for reducing the final base temperature of the heated zone. The tip presents a distal engaging surface for contacting one of the members and defines a preferably inner space located a preferred distance from the surface. A phase changing body is releasably retained within the space. At least a portion of the body changes from a first phase to a second phase by absorbing at least a portion of the heat energy during the welding program.

Abstract: According to the invention a hollow cylindrical shank of electrically conducting metal is connected to a resistance welder. A coolant supply tube passes through the shank and has an interior coolant supply passage. The coolant supply tube has an outer diameter less than the inner diameter of the hollow cylindrical shank. A weld cap seats on the shank and has a cap tip and a cap skirt that depends from the cap tip and is attached to the shank. An underside of the cap tip faces the shank and the supply tube. A coolant receiving bore formed into the underside of the weld cap extends into the cap tip to receive the coolant supply tube part way into the bore. The bore formed into the underside of the cap tip defines a bore sidewall that provides added area of heat transfer contact between the coolant and the cap tip.

Abstract: An improved cooling system for adapting to a two-component welding electrode device having a shank and cap, includes a retractable nozzle tube, a manifold, and an adjustment element for adjustably interconnecting the tube and manifold. A threaded bushing or plunger is attached to the tube and operable to adjust the distance between the interior surface of the cap and the outlet of the tube to a preferred distance. A threaded sleeve interconnects the tube and bushing for additional adjustability. The tube defines an elastically compressible bellows section, and a spacer is removably attached to the distal end of the tube for automatic adjustment of the outlet position by the cap.

Abstract: A resistance welding apparatus having a pair of programmable ball electrodes carried on universally movable positioners. The positioners are programmed to move the ball electrodes simultaneously along a seam line so that the ball electrodes clamp and support opposite sides of a pair of stacked workpieces and are electrically charged to form resistance seam welds along the seam lines to connect the workpieces.

Abstract: A curved electrode includes an installing portion to be installed in an electrode holder, an offset portion by which the offset amount is obtained, and a tip portion which comes into contact with the material to be welded W, the portions being formed separately and assembled together. A vertical hole and a horizontal hole are formed within the installing portion, an axis hole is formed within the offset portion, and a water supply tube is inserted into a cooling hole which is constructed of the vertical hole, the horizontal hole and the axis hole. C-chamfering or R-chamfering is conducted to a corner where the vertical hole and the horizontal hole intersect. An object of the present invention is to provide a curved electrode which can be manufactured easily at a low cost, and if a part of it is damaged, only that part needs to be replaced at a low cost. The durability of the curved electrode can be improved at the same time.

Abstract: An electrically and thermally conductive adapter for connecting a weld electrode to a tip holder portion of a welding device. The adapter has a first, threaded end, for removable engagement with a like-threaded receiving cavity in the tip holder. The threads may be of parallel configuration to minimize damage to the receiving cavity. The adapter has a second, preferably tapered end, for receiving a removable weld electrode. A passageway is preferably provided through the adapter for transporting cooling fluid to the electrode. An o-ring may be retained on the adapter and designed to engage with a groove in the receiving cavity in order to prevent leakage of cooling fluid from around the threads. The adapter is economical to manufacture and may be quickly and easily removed or installed to the tip holder. The adapter reduces damage to the tip holder commonly caused by the repeated changing of electrodes.

Abstract: a cooling apparatus 110 comprises a primary refrigerant circulating circuit which allows a primary refrigerant CW1 whose temperature is adjusted by a heat exchanger 138 to circulate through an electrode to adjust a temperature of the electrode, a secondary refrigerant circulating circuit which supplies a secondary refrigerant CW2 to the heat exchanger to adjust the temperature of the primary refrigerant, and a freezing circuit 140 which has a first heat exchanger 141 interposed in the secondary refrigerant circulating circuit and which adjust a temperature of the secondary refrigerant by a tertiary refrigerant. The temperature of the primary refrigerant is adjusted by the secondary refrigerant without adjusting the temperature using the freezing circuit. When a temperature of the primary refrigerant is set higher than that of the secondary refrigerant, the temperature of the primary refrigerant can be adjusted only by the secondary refrigerant.

Abstract: A weld gun for performing a welding operation on a workpiece includes a pair of opposing arms, at least one arm movable relative to the opposing arm to apply pressure to the workpiece during a welding operation. A pair of identical or mirror image side plates support components of the weld gun to establish critical dimensions of the components relative to one another, while preventing tolerance buildup of critical dimensions at critical points. A guide block is connected to one of the opposing arms. The guide block has a non-circular aperture formed therein. An electrode adapter has a non-cylindrical rod portion slidably received in the non-circular aperture formed in the guide block for preventing rotation of the electrode adapter. A hose fitting is attachable directly to a rear end of the electrode adapter for communicating with an inlet water port and an outlet water port formed in the electrode adapter for providing a routing of coolant directly through the electrode adapter only.

Abstract: A pinch type weld gun wherein the weld arms are pivotally mounted on the frame structure via a ball bearing structure including annular members of insulative material positioned in apertures in the weld arms, inner races fixedly mounted on a common pivot pin, outer races positioned within the respective insulative annular members, and ball races positioned between the respective inner races and respective outer races. A shunt is fixedly secured at one end thereof to a gun electrode and fixedly secured at another end thereof to the gun transformer, and the other end of the shunt defines a coolant passage communicating with the transformer coolant passage system whereby coolant may be delivered to the transformer coolant passage system through the coolant passage in the other end of the shunt.

Abstract: Apparatus and method for measuring weld current utilizing Hall effect sensors. The apparatus is immune from the position sensitivity drawbacks of Hall effect sensor based current memory devices through the utilization of a radially symmetrically disposed orientation of the Hall effect sensor in combination with the utilization of a summing network responsive to the output of each such sensor.

Abstract: Provided herein is a weld point electrode useful for welding weld nuts to various selected substrates.

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 welding apparatus provided with a base frame having a power source portion, an electrode die portion having a lower base portion and an upper base portion at least one of which is driven to ascend and descend to close to and part from each other, plural lower electrode portions attached to the lower base portion, and plural upper electrode portions attached to the upper base portion. Further, a lower contact conductor which electrically connects the lower electrode portions to the power source portion intermittently, and an upper contact conductor which electrically connects the upper electrode portions to the power source portion intermittently, are provided to the base frame side.

Abstract: An apparatus detects an opening in a fluid flow passageway such as occurs when a resistance welding cap which is cooled by the fluid flow becomes accidently detached from a welding machine. Upon detection of an opening, an air-actuated pinch lever is activated to quickly pinch shut flexible fluid inlet and outlet hoses and thereby shut off the fluid flow. Inlet and outlet flow rate sensors provide periodic outputs to a digital computer which determines directions of inlet and outlet flow acceleration. If either the inlet or outlet acceleration changes direction, a baseline inlet or outlet flow rate is set equal to the corresponding current flow rate value to prevent erroneous opening detection due to normal flow fluctuations. If the inlet and outlet accelerations are in the same direction, the baseline values are similarly updated. If the inlet acceleration is positive and the outlet acceleration is negative, it indicates a probable opening.

Abstract: A resistance welding electrode body is fitted with a metal pin which serves as an anchor point for an electrode welding tip. The electrode welding tip contains two lead-in notches and diagonal grooves that allow the electrode tip to be locked onto the electrode body. This form of electrode has been found advantageous in terms of retaining the electrode tip onto the electrode body during resistance spot welding.

Abstract: An apparatus detects an opening in a fluid flow passageway such as occurs when a resistance welding cap which is cooled by the fluid flow becomes accidently detached from a welding machine. Upon detection of an opening, an air-actuated pinch lever is activated to quickly pinch shut flexible fluid inlet and outlet hoses and thereby shut off the fluid flow. Inlet and outlet flow rate sensors provide periodic outputs to a digital computer which determines directions of inlet and outlet flow acceleration. If either the inlet or outlet acceleration changes direction, a baseline inlet or outlet flow rate is set equal to the corresponding current flow rate value to prevent erroneous opening detection due to normal flow fluctuations. If the inlet and outlet accelerations are in the same direction, the baseline values are similarly updated. If the inlet acceleration is positive and the outlet acceleration is negative, it indicates a probable opening.

Abstract: A copper core weld gun assembly is provided with a substantially omega (.OMEGA.) shaped cross-section taken through each arm of the assembly. Concentric copper tubes are provided to carry cooling water and electric current to the electrodes of each arm. Special fittings are provided to insure that cooling water is carried directly to and from the electrodes without contacting the body, thereby eliminating galvanization in aluminum bodies. The design includes wedge-shaped barrel locks, crown-tipped incoming water tubes, thimble-shaped female electrode caps, and provides modular design capability. A modular gun design separates the gun into three fundamental areas: (a) the electrode system; (b) the body/frame system; and (c) the moment arm design.

Abstract: A spot welding apparatus adapted particularly for joining aluminum workpieces utilizes a twisting or vibrating motion to break up oxides on the workpiece surface for improved welding and increased welding tip life. In one embodiment, a vibration inducing device is fixed to the electrode holder of a spot welding apparatus for vibrating the electrode tip during welding. In another embodiment, a camming mechanism rotates the electrode tip of the spot welding head in response to the spot welding head contacting the workpiece surface. The electrode tip rotates or twists in a limited arc after the tip contacts the workpiece to break up oxides on the workpiece surface. The electrode tip, upon removal from the workpiece surface, reverses its rotation for subsequent spot welding and to minimize the possibility of the electrode sticking to the workpiece.

Abstract: An electrical resistance welding sensor assembly useful for monitoring various resistance welding process parameters in real-time during welding operations is provided with a base element adapted to be inserted into a tapered, water-cooled, electrode tip holder, with a sensor element adapted to receive a tapered, water-cooled, electrode tip, and with an in-line integral coolant passageway extending therethrough, the sensor element having a wall component which is provided with various adhered electrical transducer devices, which conducts and transmits welding process clamping loads and electrical currents, and which is cooled by coolant flowed through the integral coolant passageway.

Abstract: An improved resistive electrode is disclosed for a welding apparatus for welding a battery terminal post to a battery bushing, The battery terminal post is electrically connected to a battery plate disposed within a battery case and the battery bushing is secured to a battery case cover with the bushing having a central bushing aperture for receiving the battery terminal post therein when the battery case cover is located on the battery case. The resistive electrode comprising a resistive electrode extending between a base end and a tip end with the base end being secured to a power source. A conductive member engages the resistive electrode for facilitating the flow of electric power from the base end to the tip end for concentrating the resistive heat proximate to the tip end of the resistive electrode.

Abstract: An apparatus and method for fusing terminal or commutator wire connections on an armature or stator, including an electrode, a pneumatic locking cylinder for driving the electrode into contact with the workpiece and applying a force to the workpiece, a load cell for measuring the force applied by the electrode, an opposition cylinder for providing an opposition force to the electrode after a cold-forming force has been reached by the electrode, a linear potentiometer for measuring the distance traveled by the electrode after the opposition force has been applied; and a locking mechanism for stopping the locking cylinder after a predetermined distance has been traveled during the weld cycle.

Abstract: A spot welding electrode includes a shank within which cooling water is communicated, and an electrode tip. The shank is provided on the top thereof with a closed head, on which the electrode tip is dismoutably fixed.

Abstract: A water cooled resistance welding assembly includes a tubular housing with an internal coolant system for efficiently removing heat from the inboard surface of a flat faced electrode for resistance welding either studs or nuts.

Abstract: This welding electrode is one wherein the welding cap 3 of the electrode body 1 carries a contact tip 4 which is securely fastened to it by brazing. Thus, the replacement of this contact tip can be carried out very easily by stopping the circulation of the cooling water in the electrodes, by applying them to a resistive metal sheet and by passing through them a current of sufficient intensity to cause the brazing ring 5 which securely fastens the contact tip 4 to the welding cap 3 to melt. The removal of a worn tip 4 and the replacement of a new tip 4 are carried out in the same manner. The welding electrode also has a contact tip 4 provided with a brazing ring 5, as well as to an automatically operating machine for replacing the tips 4 away from the line for welding the metal sheets T.

Abstract: A shut off check valve for controlling cooling fluid flow to weld tips of a resistance welding gun. The valve is disposed within the weld gun housing and selectively interrupts cooling fluid flow between fluid inlet and outlet ports.

Abstract: A spot welding electrode designed for welding coated metals such as galvanized steel and a method of welding coated metals using the spot welding electrode. The electrode includes a housing having a hollow cavity with an open end and a closed end. The cavity is surrounded by a cooling wall which has an outer surface and a parallel inner surface. The parallel surfaces provide a substantially improved and consistent cooling method for maintaining temperature at the electrode-workpiece interface below the melting point of the coating. The bulk of the heating during the weld cycle is focused at the interface of the workpiece.

Abstract: The diameter of a hafnium insert press fit into the bottom end of a copper electrode varies as a function of the level of current carried by the electrode. The diameter is the minimum necessary to support emission at that current level while also protecting the copper body against attack by the arc. The insert is generally circular and preferably extends completely through the bottom wall to a circulating flow of cooling water at a hollow interior of the electrode. The bottom wall includes an annular recess in a portion of the copper wall surrounding the insert. A coolant inlet tube extends into the recess in a spaced relationship to provide a high flow velocity of the coolant over the interior rear surface of the electrode.

Abstract: A system and method for cooling multiple weld tips of a welder. The welding system includes a housing and a plurality of weld tip plungers, each plunger being independently movable with respect to the housing, and each plunger having a mechanism for receiving a weld tip, a first port and a second port. The system also includes a primary input manifold including a mechanism for receiving fluid and at least one outlet port and a primary output manifold including a mechanism for discharging fluid and at least one inlet port. A first hose or hoses for communicating fluid from the at least one outlet port of the primary input manifold to each of the first ports of the plungers and a second hose or hoses for communicating fluid from each of the second ports of the plungers and to the at least one inlet port of the primary output manifold also are included in the system such that a fluid passing between the first and second ports of each plunger may circulate through a weld tip connected to the plunger.

Abstract: A welding nose has a digital end and a root portion joined by a plurality of surface segments having a progressively increasing outside diameter for distributing welding loads in a radial direction and for forming a plurality of smooth surfaces joined at intersections to define preformed depressions for flow of metal grains from the base material of the welding nose for reducing formation of wings on the outermost diameter of the welding nose thereby to reduce sub-surface fracturing so as to maintain a desired mean diameter over extended periods of use.

Abstract: The service life of a bottom electrode for a direct current arc furnace for producing steel is prolonged by using ZrB.sub.2 type sintered bodies for a contacting pins which constitutes a major part of the bottom electrode wherein the ZrB.sub.2 type sintered bodies have a corrosion-resistance to molten steel and slag. Further, the number of contacting pins to be used is reduced by forming each of the pins into a form of pillar with a through hole at the axis, or by assembling a plurality of longitudinally divided pin portions to form a contacting pin, whereby the diameter of the contacting pin can be made large. Then the space between contacting pins is made broad, and brick having good corrosion-resistance are filled in the space so that the service life of the bottom electrode is brought closer to that of the refractory lining of the direct current arc furnace.

Abstract: An outer surface of a resistance welding electrode tip is coated with a layer of an electrically conductive ceramic material. A preferred layer contains tungsten disulfide applied by chemical vapor deposition.

Abstract: The invention concerns an electrode for the resistance welding of sheets of surface-treated steel. A thin disk of high melting-point metal is permanently attached to the electrode's shaft or cap at the contact surface. The grain of the high melting-point metal is oriented at an angle to the axis of the electrode and the rolled-out material has a flattened grain.