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.

Systems and methods for localized work return path of additive manufacturing systems are described. Localized grounding connects the printed surface directly to the work return, and shortens the length of grounding and/or the return cables compared to substrate-based grounding.

A method of making a heat exchanger that includes providing a plurality of tubes. Each of the plurality of tubes has exterior cladding on an exterior surface, interior cladding on an interior surface, and a weld seam extending along the length of the plurality of tubes. The method further includes arranging the plurality of tubes such that each of the plurality of tubes is inserted into a corresponding header slot with the weld seams of each of the plurality of tubes oriented downward with respect to gravity, and brazing each of the plurality of tubes and the header after each tube has been inserted into a corresponding header slot. The brazing causes the interior cladding to melt and pool inside the plurality of tubes and along an interior side of the weld seams to form a clad cover portion encases debris generated while forming the weld seams.

An electrode with an interchangeable head is provided. The electrode is generally designed to provide a welding electrode having a head that may be readily removed and interchanged with other electrode heads for improved electrode repair or to affect the characteristics of the electrical arc transmitted by the electrode. The electrode includes a shaft and a head removably secured to the shaft. The head may include a first securing member and a body having a distal end that terminates at a tip having a defined tip angle. The shaft may include a proximal end having a second securing member compatible with the first securing member to removably secure the head to the shaft.

Embodiments of the present invention include a plasma cutting torch and plasma cutting torch components, such as electrodes, cathodes, retainer caps, etc. having a unique physical features, including threads relationships. Embodiments include torch components having modified square thread with a specialized thread configuration including a particular relationship between thread crest and root, and included angles of thread sidewalls.

A welding electrode for use in engaging an aluminum alloy workpiece during a spot welding process has a weld face that includes a base surface and a plurality of circular ridges that project outwardly from the base surface. The circular ridges are blunted, and their presence on the weld face provides the first welding electrode with several useful capabilities, including the ability to establish better mechanical and electrical contact with the aluminum alloy workpiece.

A domed copper electrode tip has a refractory insert inserted thereinto extending from the apogee of the dome into the interior of the electrode. The refractory insert is, preferably, a tungsten insert which is force-fitted into the interior of the electrode tip.

A resistance spot welding electrode for forming dissimilar welded lap joints in crash-relevant structural components of the automotive industry made of high-strength materials. The resistance spot welding electrode includes a cap having, at an end portion of the electrode in contact with materials to be welded together during welding, a non-axially symmetrical contact area in order to form, between the materials being welded, a weld nugget with an essentially similar non-axially symmetrical shape.

The present invention provides a welding electrode capable of spot-welding a workpiece having a surface oxide film with stable welding quality, the welding electrode allowing general tip dressers to be used. The welding electrode of the present invention is used for spot welding of a workpiece. The welding electrode includes an end face provided so as to contact the workpiece, and at least one elongated groove provided in the end face or a plurality of blind holes provided in the end face. A depth of the groove or a depth of the blind holes is 0.5 mm or more and 20 mm or less. A ratio (d/w) of the depth d of the groove to a width w of the groove or a ratio (d/s) of the depth d of the blind holes to a size s of the blind holes is 2 or more.

The present invention provides a robot control device and a spot welding system that are capable of roughening the surfaces of electrodes without requiring additional special devices or effort. The robot control device controls the operation of a robot that comprises a spot welding gun having a pair of electrodes positioned facing each other. The robot control device has a robot operation control unit that moves the pair of electrodes of the spot welding gun to a blade polishing position so that the surfaces of the pair of electrodes are polished by a rotating blade of an electrode polishing device. The robot control device changed the position of the pair of electrodes in contact with the blade from the polishing position so as to scratch the surfaces of the pair of electrodes after the polishing by the blade.