Tungsten and molybdenum electrodes for resistance welding.

In the resistance welding process, the parts to be joined are pressed together and heated by an electric current until pools of molten material form at individual points between them. This operation requires high currents and large pressing forces.

During the welding of thick sheets, the forces between the electrode and the workpiece may reach as much as 450 MPa. This represents a considerable challenge for the welding electrodes that have to withstand these loads.

Tungsten and molybdenum electrodes for resistance welding

Welding electrodes made from our refractory metals and their alloys have a relatively high level of electrical conductivity while also exhibiting outstanding stability at high temperatures. They therefore have a considerably longer service life than conventional materials such as copper and copper alloys. Take a look for yourself and use our materials to increase your electrode service lives.

Our welding electrodes made of tungsten, molybdenum and their alloys are particularly suitable for welding highly conductive materials such as copper. They are used in the following processes: Spot welding, Roller welding, Projection welding, Upset welding.

Resistance welding electrodes

Soldering versus back casting.
And the winner is ...


The better the joint between the tungsten electrode and the copper electrode is, the better and more reproducible your welding results will be. This is because defective joins reduce thermal conductivity and cause the electrical resistance of the electrode to fluctuate.

Back-casted resistance welding electrode

Below, by way of comparison, are a cross-sectional microsection of a soldered electrode insert (left) and a cross-section of our back-cast electrodes (right):

Soldered electrode
Back-cast electrode

Here, the shrink holes at the join between the base of the electrode and the shaft (left) are clearly visible. Compare this with the fault-free join of the back-cast electrode (right):

Soldered electrode
Back-cast electrode

Each image section corresponds to approximately 2500 µm.

The advantages of back-cast electrodes at a glance:

  • Reliable join between the electrode and the shaft material
  • Constant level of resistance
  • Unvarying thermal conductivity
  • Reproducible electrode quality
  • Process stability in practical application

The benefits to you: Longer service life and uniform welding parameters.

You are in a hurry? We have rods made of molybdenum, tungsten and alloys in different dimensions available on stock.

Spot welding joins two electrically conductive metal parts using the heat generated as a result of electrical resistance when an electrical current is passed through. Two electrodes press the metal sheets together and convert the welding current to heat at the contact surfaces. A large current is forced through the welding point. The metal melts at this point, thus producing the welded joint. The advantage of spot welding is that a large amount of energy can be concentrated on the spot in a very short time. The rest of the sheet is not subjected to excessive heating. Normally, sheet thicknesses will be between 0.5 and 3 mm.

WCu electrodes for projection welding.

We supply 100% infiltrated tungsten-copper comprising 75% tungsten and 25% copper for your projection welding process according to RWMA standard. This composite brings together the best of both materials: The strength of tungsten and the excellent thermal and electric conductivity of copper.

You can rely on our quality. The material properties of our WCu electrodes always remain constant. Its homogeneous microstructure means that it is easily machined.

We have WCu rods waiting in stock for you. Just take a look!

Tungsten rod

Projection welding is a modification of spot welding. In this process, the weld is made at raised sections, or projections, on one or both of the components to be joined. Heat is generated in the same way as with spot welding, except that it arises primarily in the region of the projections. Projection welding allows closer spacing of the welds. The projections can also be used for positioning. Projection welding is usually used to weld studs, nuts, and other screws to metal plates.

Tungsten electrodes for thermode welding.

We manufacture our tungsten electrodes for thermode welding according to your specifications to meet your exact needs. Extremely fine tolerances and uncompromising quality are a matter of course for us. So we can guarantee that the tips of our electrodes are free of cracks.

Thermode welding is based on the principle of resistance welding. The current only flows through the electrode rather than between the workpiece and the electrode. The narrowing at the tip of the thermode increases the resistance, producing the welding temperature at this point. The tip of the electrode is able to melt the material across very small diameters at the desired welding Point.

Why do our WCu electrodes last so long? Get to know in only 90 seconds.

Questions about materials? Please ask.

With our wide range of materials, we are equipped to meet the most varied requirements. Molybdenum, tungsten or one of our many alloys? We would be delighted to advise you personally about the materials that are most suitable for your applications.

You can rely on our experience in the machining of top-quality refractory materials and welding electrodes.

Your contact person
Your contact Person for:
David Morrison
Give me a call:
+1 508-878-3758
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David Morrison