Spot welding electrode and welding apparatus and welding method using same

Abstract

A spot welding electrode of a donut-shaped electrode wherein even when a welded member of a steel sheet is slanted with respect a plane perpendicular to an axis of the spot welding electrode, a cross tensile strength (CTS) of the spot welded joint can be improved. The donut shape spot welding electrode according to the present invention has an electrode tip and an electrode support. The electrode tip contacts the electrode support to be able to move. Due to this, it is possible to strikingly raise the ability of the donut-shaped electrode to track a steel sheet and make the entire surface of the donut shape contact-and-conduction part contact the steel sheet, so it is possible to secure a high CTS value even if the steel sheet is slanted.

Claims

1. A spot welding electrode, having comprising: an electrode tip having a donut shape contact-and-conduction part; and an electrode support supporting the electrode tip, wherein said electrode tip contacts said electrode support to be able to swing, wherein said donut shape contact-and-conduction part has an insulating member placed at its center, and wherein said electrode tip and said electrode support are supported together by a spring enabling the electrode tip to be pushed against the electrode support.

2. The spot welding electrode according to claim 1, wherein a tail of said electrode tip and a head of said electrode support, forming contact parts of said electrode tip and said electrode support, are spherical crown shapes.

3. The spot welding electrode according to claim 2, wherein radii of curvature of said tail of said electrode tip and said head of said electrode support are 4 mm to 20 mm and a radius of curvature of said tail of said electrode tip is 5% to +10% of a radius of curvature of said head of the electrode support.

4. The spot welding electrode according to claim 2, wherein in said contact-and-conduction part, an area of a contact-and-conduction surface contacting and conductive with a welded member is 12 mm.sup.2 to 70 mm.sup.2 and a diameter D of a smallest circle surrounding said contact-and-conduction surface is 8 mm to 20 mm.

5. The spot welding electrode according to claim 2, wherein in said contact-and-conduction part, a contact-and-conduction surface contacting and conductive with a welded member is a closed curve of a circular ring, elliptical ring, or n-sided polygon (n3) with a 0.3 mm to 2.5 mm width.

6. The spot welding electrode according to claim 3, wherein in said contact-and-conduction part, an area of a contact-and-conduction surface contacting and conductive with a welded member is 12 mm.sup.2 to 70 mm.sup.2 and a diameter D of a smallest circle surrounding said contact-and-conduction surface is 8 mm to 20 mm.

7. The spot welding electrode according to claim 3, wherein in said contact-and-conduction part, a contact-and-conduction surface contacting and conductive with a welded member is a closed curve of a circular ring, elliptical ring, or n-sided polygon (n3) with a 0.3 mm to 2.5 mm width.

8. The spot welding electrode according to claim 1, wherein in said contact-and-conduction part, an area of a contact-and-conduction surface contacting and conductive with a welded member is 12 mm.sup.2 to 70 mm.sup.2 and a diameter D of a smallest circle surrounding said contact-and-conduction surface is 8 mm to 20 mm.

9. The spot welding electrode according to claim 8, wherein in said contact-and-conduction part, a contact-and-conduction surface contacting and conductive with a welded member is a closed curve of a circular ring, elliptical ring, or n-sided polygon (n3) with a 0.3 mm to 2.5 mm width.

10. The spot welding electrode according to claim 1, wherein in said contact-and-conduction part, a contact-and-conduction surface contacting and conductive with a welded member is a closed curve of a circular ring, elliptical ring, or n-sided polygon (n3) with a 0.3 mm to 2.5 mm width.

11. The spot welding electrode according to claim 1, wherein metal used for said electrode tip and said electrode support is copper or a copper alloy.

12. A spot welding apparatus for spot welding at least two steel sheets, the spot welding apparatus comprising at least one spot welding electrode according to claim 1.

13. A spot welding method for spot welding at least two steel sheets, the spot welding method comprising using at least one spot welding electrode according to claim 1.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) FIG. 1A-1 to FIG. 1B are conceptual views showing one embodiment of a spot welding electrode according to the present invention. They show the case where the contact-and-conduction part is a split circular ring shape and the electrode tip tail is a recessed spherical crown. FIG. 1A-1 is a bird's eye view of the electrode tip from the contact-and-conduction part side. FIG. 1A-2 is a cross-sectional view along the electrode axis of the electrode tip and a cross-sectional view along A-A of FIG. 1A-1. FIG. 1B is a view showing an electrode support.

(2) FIG. 2A-1 to FIG. 2B are conceptual views showing one embodiment of a spot welding electrode according to the present invention. They show the case where the contact-and-conduction part is formed by arc shapes and the electrode tip tail is a projecting spherical crown. FIG. 2A-1 is a bird's eye view of the electrode tip from the contact-and-conduction part side. FIG. 2A-2 is a cross-sectional view along the electrode axis of the electrode tip and a cross-sectional view along B-B of FIG. 2A-1. FIG. 2B is a view showing an electrode support.

(3) FIG. 3A-1 to FIG. 3B are conceptual views showing one embodiment of a spot welding electrode according to the present invention. They show the case where the contact-and-conduction part is formed by arc shapes and the electrode tip tail is a recessed spherical crown larger than a half sphere. The explanations of FIG. 3A-1, FIG. 3A-2, and FIG. 3B are based on FIG. 1A-1 to 1B.

(4) FIG. 4A-1 to FIG. 4B are conceptual views showing one embodiment of a spot welding electrode according to the present invention. They show the case where the contact-and-conduction part is formed by arc shapes and the electrode tip tail is a projecting spherical crown larger than a half sphere. The explanations of FIG. 4A-1, FIG. 4A-2, and FIG. 4B are based on FIGS. 2A-1 to 2B.

(5) FIG. 5 is a view for explaining one embodiment of a spot welding electrode according to the present invention having a spring holding mechanism.

(6) FIG. 6 is a view for explaining one embodiment of a spot welding electrode according to the present invention having a spring holding mechanism.

(7) FIG. 7 is a view showing the concept when placing spot welding electrodes according to the present invention straddling slant steel sheets.

(8) FIGS. 8A-1 to 8B are conceptual views showing one embodiment of a spot welding electrode according to the present invention. They show the case where the contact-and-conduction part is a circular ring shape and the electrode tip tail is a recessed spherical crown. The explanations of FIG. 8A-1, FIG. 8A-2, and FIG. 8B are based on FIGS. 1A-1 to 1B.

(9) FIGS. 9A-1 to 9B is conceptual views showing one embodiment of a spot welding electrode according to the present invention. They show the case where the contact-and-conduction part is a circular ring shape and the electrode tip tail is a projecting spherical crown. The explanations of FIG. 9A-1, FIG. 9A-2, and FIG. 9B are based on FIGS. 1A-1 to 1B.

(10) FIGS. 10A-1 to 10B are conceptual views showing one embodiment of a spot welding electrode according to the present invention. They show the case where the contact-and-conduction part is a hexagonal shape and the electrode tip tail is a recessed spherical crown. The explanations of FIG. 10A-1, FIG. 10A-2, and FIG. 10B are based on FIGS. 1A-1 to 1B.

(11) FIGS. 11A-1 to 11B are conceptual views showing one embodiment of a spot welding electrode according to the present invention. They show the case where the contact-and-conduction part is a hexagonal shape and the electrode tip tail is a recessed spherical crown. The explanations of FIG. 11A-1, FIG. 11A-2, and FIG. 11B are based on FIGS. 1A-1 to 1B.

(12) FIGS. 12A-1 to 12B are conceptual views showing one embodiment of a spot welding electrode according to the present invention. They show the case where the contact-and-conduction part is a split circular ring shape and the electrode tip tail is a recessed spherical crown. The explanations of FIG. 12A-1, FIG. 12A-2, and FIG. 12B are based on FIGS. 1A-1 to 1B.

(13) FIGS. 13A-1 to 13B are conceptual views showing one embodiment of a spot welding electrode according to the present invention. They show the case where the contact-and-conduction part is a split circular ring shape and the electrode tip tail is a recessed spherical crown. The explanations of FIG. 13A-1, FIG. 13A-2, and FIG. 13B are based on FIGS. 1A-1 to 1B.

(14) FIGS. 14A and 14B are views for explaining the concept of an apparatus equipped with of spot welding electrodes according to the present invention. FIG. 14A shows the case of use of spot welding electrodes shown in FIGS. 1A-1 to 1B at the top and bottom, while FIG. 14B explains the case of use of a spot welding electrode shown in FIGS. 1A-1 to 1B at one side and the case of use of a conventional spot welding electrode at the other side.

(15) FIGS. 15A and 15B are views for explaining the concept of an apparatus equipped with of spot welding electrodes according to the present invention. FIG. 15A shows the case of use of spot welding electrodes shown in FIGS. 2A-1 to 2B at the top and bottom, while FIG. 15B explains the case of use of a spot welding electrode shown in FIGS. 2A-1 to 2B at one side and the case of use of a conventional spot welding electrode at the other side.

(16) FIGS. 16A and 16B are views for explaining an example of use of the spot welding electrodes according to the present invention. FIG. 16A shows the case of use of spot welding electrodes shown in FIGS. 1A-1 to 1B at the top and bottom, while FIG. 16B explains the case of use of a spot welding electrode shown in FIGS. 1A-1 to 1B at one side and the case of use of a conventional spot welding electrode at the other side.

(17) FIGS. 17A and 17B are views for explaining an example of use of the spot welding electrodes according to the present invention. FIG. 17A shows the case of use of spot welding electrodes shown in FIGS. 2A-1 to 2B at the top and bottom, while FIG. 17B explains the case of use of a spot welding electrode shown in FIGS. 2A-1 to 2B at one side and the case of use of a conventional spot welding electrode at the other side.

(18) FIG. 18 is a view for explaining the concept of a spot welding apparatus using conventional spot welding electrodes.

(19) FIGS. 19A and 19B are views for explaining the concept of a conventional spot welding electrode. FIG. 19A is a view when viewing the conventional spot welding electrode from the head, while FIG. 19B shows a K-K cross-section in FIG. 19A.

(20) FIG. 20 is a view showing a relationship between a slant angle of steel sheets and a CTS value after spot welding.

DESCRIPTION OF EMBODIMENTS

(21) Details of the present invention will be explained below. As explained above, in this Description, the welded members will be explained as steel sheets.

(22) The spot welding electrode according to the present invention has an electrode tip and an electrode support supporting the same. At one end of the electrode tip, there is a contact-and-conduction part for contacting a steel sheet and causing electrical conduction. The contact-and-conduction part of the electrode according to the present invention has the shape of a donut for obtaining a donut-shaped nugget. Here, a donut shape indicates a continuous closed curve having a width not 0 or a plurality of a group of arcs or line segments having widths not 0 present on a closed curve. Of course, it includes a circular ring shape of consecutive arcs (total circumference), a group of arcs present on the same circle (also called split circular ring), and elliptical shapes and polygonal shapes (in particular projecting polygonal shapes are preferred). However, when split into a plurality of arcs or line segments having widths not 0 on a closed curve, a smaller number of splits is preferable, specifically four or less splits are preferable.

(23) The electrode support is supported by an electrode holder. The axis of the electrode support matches with the axis of the spot welding electrode (electrode axis). A pair of the spot welding electrodes are placed facing each other across the steel sheets and current is run across the two electrodes to heat the sheets, so usually the pair of facing electrode axes match.

(24) The electrode tip is structured to be supported at one end of the electrode support while able to move with respect to the electrode support. The electrode tip being able to move means the electrode tip can track a steel sheet even if the steel sheet slants with respect to the plane perpendicular to the electrode axis (reference plane). Due to this, the entire surface of the contact-and-conduction part can contact the steel sheet. So long as structured to be able to track a slanted steel sheet, the structure is not particularly limited. In particular, if structured so that the electrode tip can swing about the electrode axis, the electrode tip can rotate about the electrode axis and can track even steel sheet slanted with respect to the reference plane.

(25) For example, the contact parts of the electrode tip and electrode support, that is, the tail of the electrode tip and the head of the electrode support, may be made spherical crown shapes which fit with each other. For example, as shown in FIG. 1A-1 to FIG. 1B, they may be structured so that the tail of the electrode tip is a recessed spherical crown shape, the head of the electrode support is a projecting spherical crown shape, and the two fit and slide with each other. According to this structure, the electrode tip can swing in all directions about the center of curvature of the spherical crown forming the head of the electrode support and can track a steel sheet slanted from the reference plane. FIGS. 2A-1 to FIG. 2B to FIG. 4A-1 to FIG. 4B are examples of application.

(26) FIG. 7 shows the state where spot welding electrodes shown in FIG. 1A-1 to FIG. 1B are made to face each other and steel sheets slanted with respect to a reference plane are placed between the electrodes. The electrode tips track the slant 0 of the steel sheets and swing by exactly 0 with respect to the electrode axes so that the front surfaces of the contact-and-conduction parts at first ends of the electrode tips contact the steel sheets. At this time, as clear from FIG. 7 as well, the center lines of the contact-and-conduction parts of the facing electrodes (center lines of conduction) do not match. For this reason, the stability of the nugget shape changes depending on the slant angle of the steel sheets. The inventors investigated the slant angle of steel sheets and the stability of the nugget shape by experiments.

(27) FIG. 20 shows the results of investigation of the slant angle of the sheet sheets and stability of the nugget shape using spot welding electrodes according to the present invention, conventional donut-shaped electrodes, and conventional point-shaped electrodes. For the electrodes according to the present invention, No. 5 of Table 2 was used. For the conventional donut-shaped electrodes, No. 2 of Table 2 was used. The conventional point electrodes were generally commercially available electrodes. The indicator of stability of the nugget shape was the CTS value after spot welding.

(28) As clear from FIG. 20 as well, if there is no steel sheet slant (=0), by using donut-shaped electrodes, the CTS value becomes about 1.8 times that of the conventional point electrodes and therefore the effect of the donut shape was verified. However, along with the increase of the steel sheet slant, the donut-shaped electrodes become the one-sided contact state resulting in point contact, so the CTS value rapidly falls and becomes equal to that of conventional point-shaped electrodes at a 5 or so slant.

(29) As opposed to this, the electrodes according to the present invention are not affected much at all by the steel sheet slant if about 5. As the steel sheet slant increases, the conduction offset increases, so the CTS value falls. However, this fall is slight. Even with a steel sheet slant angle of 20 (=20), the value only falls about 17%. An approximately five-fold CTS value was obtained compared with point-shaped electrodes or conventional donut-shaped electrodes.

(30) Here, the geometric relationship of the electrodes according to the present invention will be verified. Here, the length between centerlines of the facing contact-and-conduction parts (conduction offset) is made L, the radius of a contact-and-conduction part (donut shape) is made A, the minimum thickness of an electrode tip (distance between apex of spherical crown part and tip of contact-and-conduction part) is made h, the steel sheet thickness is made t, and the radius of curvature of the spherical crown of the head of an electrode support is made a. The steel sheets for spot welding are the same in thickness. Two are superposed for welding. In this case, the following relationship stands geometrically.
L=(2a+2h+2t)tan

(31) Unless the projections of the front and back contact-and-conduction parts on the steel sheets at least overlap, the nugget shape will become unstable. Therefore, the following relationship is necessary.
2A>L

(32) That is, to obtain a nugget shape, the following relationship must be satisfied:
A>(a+h+t)tan

(33) For example, in the No. 5 electrode of Table 2 used in the experiments, if a=8 mm, h=3 mm, A=6 mm, and t=2.6 mm, then tan <0.44. That is, it is learned that if <23.8, the nugget shape is stable and a high CTS is obtained. While depending also on the electrode or steel sheet thickness or other shape conditions as explained above, it is learned that if a spot welding electrode according to the present invention, with at least a steel sheet slant angle of up to about 10, the nugget shape stabilizes and a wide circumferential length nugget is obtained, so a high CTS value can be secured.

(34) Next, measures for suppressing abnormal conduction due to deformation of the steel sheets during the spot welding will be explained. Even if using the electrodes according to the present invention, as the steel sheet thickness becomes thinner, deformation of the steel sheets at the time of spot welding is unavoidable. For this reason, contact with the center (recessed sunken part) of a contact-and-conduction part of the donut shape becomes easy. Furthermore, if a donut shape contact-and-conduction part increases in diameter, contact becomes further easier. If the steel sheets contact the center of a donut shape contact-and-conduction part and current ends up running through even the center (abnormal conduction), the nugget shape does not become stable leading to a fall in the CTS value. In fact, even during a spot welding experiment of thin-gauge steel sheets, the above-mentioned abnormal conduction occurs with a probability of several percent. This abnormal conduction causes a drop in the reliability of the spot welding. The inventors solved this problem by placing an insulating member at the center of the donut shape contact-and-conduction part (recessed sunken part) so that conduction does not occur even if a steel sheet deforms. Here, the insulating member may be a material with an internal resistance of 10.sup.5/m or more. This is because if less than 10.sup.5/m, with the voltage used in spot welding, insulation breakdown is liable to occur and conduction to result. The thickness of the insulating member should be 0.1 mm or more. If the thickness is less than 0.1 mm, the loss due to the heat at the time of welding is liable to cause consumption of the insulating substance.

(35) Next, an electrode according to the present invention will be explained using examples of embodiments.

First Embodiment

(36) A first embodiment of the present invention is a metal welding use electrode having an electrode tip and an electrode support where the tail of the electrode tip is recessed.

(37) FIG. 1A-1 to FIG. 1B and FIG. 3A-1 to FIG. 3B show a spot welding electrode with a tail of the electrode tip of a recessed shape. FIGS. 1A-1 to FIG. 1B show a spot welding electrode with a recessed tail of the electrode tip where the tail 13 of the electrode tip and the head 23 of the electrode support mechanically contact and with a sliding surface of a spherical crown shape smaller than the radius. FIG. 3A-1 to FIG. 3B show a spot welding electrode with a recessed tail of the electrode type of a spherical crown shape where the tail 13 of the electrode tip and the head 23 of the electrode support mechanically contact and the sliding surface is larger than the radius. The only point of difference is the sliding area by which the tail 13 of the electrode tip and the head 23 of the electrode support mechanically contact. Therefore, to avoid overlapping explanations, below, the explanation will be given in accordance with FIG. 1A-1 to FIG. 1B.

(38) Support

(39) FIG. 1B shows an electrode support, where 23 is the head of the electrode support and 22 is the tail of the support.

(40) (a) Form and Function

(41) The function of the head 23 of the electrode support is to support the electrode tip 1 from the tail 13 of the electrode tip. The electrode support 2 has a bullet-shaped form. The head of the electrode support has a projecting spherical crown shape with a radius of curvature of 4 to 20 mm (in the figure, a semispherical shape). The remaining part is cylindrical. The head 23 of the electrode support contacts and supports the tail 13 of the electrode tip 1. The reason why the head 23 of the electrode support is made a projecting shape with a radius of curvature of 4 to 20 mm is that if the radius of curvature is less than 4 mm), 1) the region where the head 23 of the electrode support and the tail 13 of the electrode tip electrically contact becomes narrower and they are liable to fuse together and 2) the head 23 of the electrode support and the tail 13 of the electrode tip cannot withstand the load by which the electrode is pressed. Further, if the radius of curvature is over 20 mm, the displacement of the electrode tip 1 becomes larger and control of displacement of the electrode tip 1 becomes difficult. While not shown, the tail 22 of the electrode support is connected with an external power supply.

(42) (b) Metal Material

(43) The metal material forming the electrode support is required to be high in electrical conductivity and high in strength, so pure Cu or Cu alloy is preferable. A CuCr alloy is also preferable.

(44) Tip

(45) (a) Form and Function

(46) The head 11 of the electrode tip has a contact-and-conduction part 14. This supplies current to the steel sheets. In the contact-and-conduction part 14, the part contacting and conductive with a steel sheet will be called the contact-and-conduction surface 15. The tail 13 of the electrode tip is supported by the head 23 of the electrode support. Current is supplied from the electrode support 2. The tail 13 of the electrode tip has a recess with a radius of curvature of 5% to +10% of the radius of curvature of the head 23 of the electrode support of the support 2. If the radius of curvature is over 10%, the region where the tail 13 of the electrode tip and the head 23 of the electrode support electrically contact becomes smaller and they are liable to end up fusing together due to the concentration of current. On the other hand, if less than 5%, the tail 13 of the electrode tip and the head 23 of the electrode support become large in contact resistance at their centers and the flow of current becomes harder. Even if the electrode axes of the facing spot electrodes are offset, the electrode tip can slide on the head 23 of the electrode support and therefore the contact-and-conduction surface can evenly contact the steel sheet. In this way, the current supplied from the contact-and-conduction surface 15 can be used to stably form a nugget with a long outer circumference at the steel sheet.

(47) (b) Metal Material

(48) The material of the metal forming the electrode tip 1 is required to be high in electrical conductivity and high in strength, so is preferably pure Cu or Cu alloy. A CuCr alloy is preferable.

(49) Contact-and-Conduction Surface Etc.

(50) (a) Shape

(51) The total S of the area of the contact-and-conduction surface of the contact-and-conduction part 14 positioned at the head 11 of the electrode tip (below, referred to as the area of the contacting and conduction surface) should be 12 mm.sup.2 to 70 mm.sup.2. If the area of the contact-and-conduction surface is less than 12 mm.sup.2, the current density at the contact-and-conduction part becomes high and the generated heat causes the wear of the electrode to become greater. On the other hand, if over 70 mm.sup.2, the current density falls and the heat density required for melting (amount of heat generated per unit volume of the steel material) can no longer be obtained. The area of the contact-and-conduction surface is preferably 20 mm.sup.2 to 60 mm.sup.2, more preferably 30 mm.sup.2 to 40 mm.sup.2. The shape of the contact-and-conduction surface 15 is preferably a circle or ellipse such as shown in FIGS. 8A-1 to 8B or a closed curve such as an n-sided polygon (n3) such as shown in FIGS. 10A-1 to 10B.

(52) (b) Diameter of Smallest Surrounding Circle

(53) The diameter D of the smallest circle surrounding all of the contact-and-conduction surface (below, referred to as the smallest surrounding circle) is an important element. FIG. 1A-1 to FIG. 1B shows the case where the contact-and-conduction part 14 is scattered in island shapes. The circle drawn by the broken line 16 is the smallest surrounding circle. The diameter D of the smallest surrounding circle should be 8 mm to 20 mm. If the diameter of the smallest surrounding circle is 8 mm or less, a sufficiently large nugget cannot be formed. On the other hand, if over 20 mm, the weld area of the steel sheet ends up becoming larger, which is inefficient. The diameter of the smallest surrounding circle is preferably 10 mm to 16 mm, more preferably 12 mm to 15 mm.

(54) (c) Insulating Substance

(55) When the contact-and-conduction surface 15 draws a closed curve, the space inside the closed curve may have a ceramic or other insulating member with a high heat resistance other than air inside it. By having the insulating member, it is possible to prevent deformation of a steel sheet at the time of spot welding from causing the steel sheet to contact the recess of the closed curve side (also referred to as the center) and from causing abnormal conduction. Furthermore, by the center having the insulating member, the contact-and-conduction surface 15 and the center become the same plane, so the shock when the contact-and-conduction surface 15 contacts the steel sheet is eased. Using the electrode of FIGS. 8A-1 to 8B as an example, an example of placement of the insulating member 32 at the inside of the contact-and-conduction part 14 will be shown.

(56) Holding Springs

(57) FIG. 5 is a view for explaining a spot welding electrode equipped with holding springs according to the present invention. In FIG. 5, 19 indicates spring hooks for holding the electrode tip, 29 indicate spring hooks for holding the electrode support, and 39 indicates holding springs. As shown in FIG. 5, the holding springs 39 enable the electrode tip 1 to be pushed against the electrode support 2.

Second Embodiment

(58) The second embodiment of the present invention is a metal welding electrode having an electrode tip and an electrode support wherein the tail of the electrode tip is a projecting type.

(59) FIG. 2A-1 to FIG. 2B and FIG. 4A-1 to FIG. 4B show a spot welding electrode with a recessed tail of the electrode tip. The electrode of FIG. 2A-1 to FIG. 2B differs from the electrode of FIG. 1A-1 to FIG. 1B in that the tail of the electrode tip is recessed, but the other requirements and the substantive functions are the same as the electrode of FIG. 1A-1 to FIG. 1B. In the same way, the electrode of FIG. 4A-1 to FIG. 4B differs from the electrode of FIG. 3A-1 to FIG. 3B in that the tail of the electrode tip is recessed. The other requirements and substantive functions are the same as the electrode of FIG. 4A-1 to FIG. 4B. Here, overlapping explanations are avoided, but the electrode of the first embodiment and the electrode of the second embodiment have substantially the same functions.

(60) Spot Welding Apparatus

(61) FIGS. 14A and 14B are conceptual views of a spot welding apparatus using electrodes of a first embodiment, while FIGS. 15A and 15B are conceptual views of a spot welding apparatus using electrodes of the second embodiment. As shown in FIG. 14A and FIG. 15A, sometimes the electrode according to the present invention is applied for both of the facing electrodes, while as shown in FIG. 14B and FIG. 15B, sometimes it is applied for just one. Even if the electrode holder itself deforms and the axes of the facing two electrodes cross at a slant, by applying the electrode according to the present invention to one electrode, the two electrodes can suitably contact the steel sheets. As shown in FIGS. 14A and 14B and FIGS. 15A and 15B, by applying the spot welding electrode according to the present invention for at least one of the two facing electrodes, it is possible to obtain a stable nugget even with a donut-shaped electrode.

(62) Spot Welding Method

(63) FIGS. 16A and 16B are conceptual views of a spot welding method using an electrode of the first embodiment, while FIGS. 17A and 17B are conceptual views using an electrode of the second embodiment. As shown in FIG. 16A and FIG. 17A, sometimes the electrode according to the present invention is applied for both of the facing electrodes, while as shown in FIG. 16B and FIG. 17B, sometimes it is applied for just one. As shown in FIG. 16 and FIG. 17, by using the spot welding electrode according to the present invention for at least one of the two facing electrodes, it is possible to obtain a stable nugget even with a donut-shaped electrode.

EXAMPLES

(64) Spot welding was performed by the conditions shown in Table 1 and Table 2. For comparison, the steel sheet slant angles were changed to 0, 5, 10, and 20 to measure the CTS. The CTS was tested in accordance with JIS Z 3137 (1999).

(65) The steel sheet slant angle, as shown in FIG. 7, means the angle formed by the plane perpendicular to the electrode axis (center axes of facing electrodes) and a steel sheet when using an electrode of the present invention.

(66) The contact-and-conduction part was based on a donut shape (circular ring shape shown in FIGS. 8A-1 to 8B and FIGS. 9A-1 to 9B) made a split circular ring (shape of split circular ring shown in FIGS. 12A-1 to 12B and FIGS. 13A-1 to 13B) or hexagonal ring (hexagonal shape shown in FIGS. 10A-1 to 10B and FIGS. 11A-1 to 11B). No. 1 and No. 2 are comparative examples. In the conventional spot welding electrodes, a point-shaped electrode (disk shaped contact-and-conduction part) was made No. 1, while a donut shape (circular ring shape) electrode was made No. 2.

(67) As invention examples and comparative examples of No. 3 to No. 9, No. 14 to No. 29, No. 34, and No. 35, spot welding electrodes of the present invention shown in FIGS. 8A-1 to 8B with contact-and-conduction surfaces of donut shapes (circular ring shapes) and recessed tails of electrode tips (first embodiment) were used.

(68) Note that, in the invention examples of No. 34 and No. 35, the shape when viewing the contact-and-conduction surface 15 from right above the tip 1 is a closed curve. At the space at the inside of the sealed curve, there is an insulating member. In the case of the invention example of No. 34, mica was attached, while in the case of the invention example of No. 35, silicon nitride was attached.

(69) The steel sheets and welding conditions used for the examples are shown in Table 1. Further, the dimensions of the electrodes used in the examples are shown in Table 2.

(70) The results are shown in Table 3. In the evaluation, the CTS [kN]=7.1 at the time of a steel sheet slant angle 0 in the point-shaped electrode usually used in No. 1 is made the base. The change with respect to this was defined as the base ratio [%]. Further, in each test electrode, the ratio between the CTS value at the time of a slant angle 0 and the CTS values at the time of the slant angles 5, 10, and 20 was made the CTS ratio (%). If the CTS ratio is 60% or more, the result was evaluated as passing (good) while otherwise it was evaluated as failing (poor).

CASE OF INVENTIVE EXAMPLES

(71) Nos. 4 to 8, 11, 12, 15 to 17, 20 to 24, and 26 to 35 are invention examples. According to Table 3, it was confirmed that if applying the spot electrode of the present invention (recessed shape of tail of electrode tip), even if the steel sheet slant angle is 20 or so, deterioration of the CTS can be prevented.

CASE OF COMPARATIVE EXAMPLES

(72) Nos. 1, 2, 3, 9, 10, 13, 14, 18, 19, and 25 are comparative examples.

(73) According to Table 3, Nos. 14 and 18 are examples where the sliding parts fused together thereby making welding impossible, No. 19 is an example where the contact parts melted thereby making welding impossible, and No. 25 is an example where a nugget could not be formed. Further, it was confirmed that even if not able to be welded, if the slant angle becomes 20 or so, the CTS greatly deteriorates from the base.

(74) Furthermore, these results are graphed in FIG. 20. While explained above, as clear from FIG. 20, when there is no steel sheet slant (=0), by making the electrode donut-shaped, the CTS value becomes about 1.8 times that of a conventional point electrode, so the effect of the donut shape is verified. However, along with an increase of the steel sheet slant, the donut-shaped electrode ends up one-sided in contact resulting in point contact, so the CTS value rapidly falls and becomes equal to that of a conventional point type electrode with a slant of about 5.

(75) As opposed to this, the electrode according to the present invention is not affected much at all by the steel sheet slant at 5 or so. As the steel sheet slant increases, the offset increases during conduction, so the CTS value falls. However, the drop is slight. Even with a steel sheet slant angle of 20 (=20), it only falls about 17%. A CTS value of about 5 times a point electrode or conventional donut-shaped electrode was obtained. Above, the present invention was explained, but the present invention is not limited to the above examples. If satisfying the requirements of the present invention, the effects can be obtained.

(76) TABLE-US-00001 TABLE 1 Steel sheet strength 980 MPa class Sheet thickness 1.2 mm Pressing force 3 kN Current value 8 kA Conduction time 300 ms

(77) TABLE-US-00002 TABLE 2 Shape of electrode Contact-and-conduction surface 15 Radius of Radius of Difference of Form of Diameter D Conduction curvature curvature radius of contact-and- of smallest part Height of of head of of head of curvature of conduction surrounding width/ Area conduction No. Type Sliding method support/mm support/mm recess/% part circle/mm mm S/mm.sup.2 part/mm 1 Comp. No sliding Circle 8 50.24 0.5 ex. 2 Comp. No sliding Circular ring 12 1 34.54 0.5 ex. 3 Comp. Projecting shape of 3 3.05 1.7 Circular ring 12 1 34.54 0.5 ex. head of support 4 Inv. Projecting shape of 4 4.05 1.3 Circular ring 12 1 34.54 0.5 ex. head of support 5 Inv. Projecting shape of 8 8.05 0.6 Circular ring 12 1 34.54 0.5 ex. head of support 6 Inv. Projecting shape of 12 12.05 0.4 Circular ring 12 1 34.54 0.5 ex. head of support 7 Inv. Projecting shape of 16 16.05 0.3 Circular ring 12 1 34.54 0.5 ex. head of support 8 Inv. Projecting shape of 20 20.05 0.2 Circular ring 12 1 34.54 0.5 ex. head of support 9 Comp. Projecting shape of 22 22.05 0.2 Circular ring 12 1 34.54 0.5 ex. head of support 10 Comp. Projecting shape of 3.05 3 0.7 Circular ring 12 1 34.54 0.5 ex. head of support 11 Inv. Projecting shape of 4.05 4 1.3 Circular ring 12 1 34.54 0.5 ex. head of support 12 Inv. Projecting shape of 20.05 20 0.2 Circular ring 12 1 34.54 0.5 ex. head of support 13 Comp. Projecting shape of 22.05 22 0.3 Circular ring 12 1 34.54 0.5 ex. head of support 14 Comp. Projecting shape of 8 7.2 10.0 Circular ring 12 1 34.54 0.5 ex. head of support 15 Inv. Projecting shape of 8 7.6 5.0 Circular ring 12 1 34.54 0.5 ex. head of support 16 Inv. Projecting shape of 8 8.4 5.0 Circular ring 12 1 34.54 0.5 ex. head of support 17 Inv. Projecting shape of 8 8.8 10.0 Circular ring 12 1 34.54 0.5 ex. head of support 18 Comp. Projecting shape of 8 9 12.5 Circular ring 12 1 34.54 0.5 ex. head of support 19 Comp. Projecting shape of 8 8.05 0.6 Circular ring 12 0.3 11.02 0.5 ex. head of support 20 Inv. Projecting shape of 8 8.05 0.6 Circular ring 12 0.4 14.57 0.5 ex. head of support 21 Inv. Projecting shape of 8 8.05 0.6 12 0.5 18.06 0.5 ex. head of support 22 Inv. Projecting shape of 8 8.05 0.6 12 1.5 49.46 0.5 ex. head of support 23 Inv. Projecting shape of 8 8.05 0.6 12 2 62.80 0.5 ex. head of support 24 Inv. Projecting shape of 8 8.05 0.6 12 2.2 67.70 0.5 ex. head of support 25 Comp. Projecting shape of 8 8.05 0.6 12 2.4 72.35 0.5 ex. head of support 26 Inv. Projecting shape of 8 8.05 0.6 9 1 25.12 0.5 ex. head of support 27 Inv. Projecting shape of 8 8.05 0.6 13 1 37.68 0.5 ex. head of support 28 Inv. Projecting shape of 8 8.05 0.6 17 1 50.24 0.5 ex. head of support 29 Inv. Projecting shape of 8 8.05 0.6 20 1 59.66 0.5 ex. head of support 30 Inv. Projecting shape of 8 8.05 0.6 FIG. 10 12 1 32.81 0.5 ex. head of support 31 Inv. Projecting shape of 8 8.05 0.6 Hexagonal ring 12 1 28.58 0.5 ex. head of support 32 Inv. Projecting shape of 8 8.05 0.6 Circular ring 12 1 34.54 0.5 ex. head of support (inside mica) 33 Inv. Projecting shape of 8 8.05 0.6 Circular ring 12 1 34.54 0.5 ex. head of support (inside silicon nitride)

(78) TABLE-US-00003 TABLE 3 Slant angle 10 Slant angle 5 CTS ratio Slant angle 20 Slant angle 0 CTS ratio with CTS ratio Base Base with slant Base slant Base with slant Weld- CTS ratio CTS ratio angle 0 CTS CTS ratio angle 0 CTS CTS ratio angle 0 CTS Judg- No. Type ability (kN) (%) (kN) (%) (%) eval. (kN) (%) (%) eval. (kN) (%) (%) eval. ment 1 Comp. ex. 7.1 Base 5.2 26.8 73.2 Good 3.6 49.3 50.7 Poor 1.8 74.6 25.4 Poor Poor 2 Comp. ex. 12.9 82.7 4.8 32.4 37.2 Poor 2.4 66.2 18.6 Poor 1.6 77.5 12.4 Poor Poor 3 Comp. ex. 12.8 77.5 10.4 46.5 82.5 Good 5.4 23.9 42.9 Poor 3.6 49.3 28.6 Poor Poor 4 Inv. ex. 11.6 63.4 12 69.0 103.4 Good 10.8 52.1 93.1 Good 10.2 43.7 87.9 Good Good 5 Inv. ex. 12.3 73.2 12.5 76.1 101.6 Good 11.2 57.7 91.1 Good 9.6 35.2 78.0 Good Good 6 Inv. ex. 12.5 76.1 12.6 77.5 100.8 Good 11.8 66.2 94.4 Good 10.7 50.7 85.6 Good Good 7 Inv. ex. 12.2 71.8 12 69.0 98.4 Good 11.6 63.4 95.1 Good 10.5 47.9 86.1 Good Good 8 Inv. ex. 10.8 52.1 11.4 60.6 105.6 Good 9.8 38.0 90.7 Good 7.6 7.0 70.4 Good Good 9 Comp. ex. 11.5 62.0 7.5 5.6 65.2 Good 5.8 18.3 50.4 Poor 3.2 54.9 27.8 Poor Poor 10 Comp. ex. 12.4 74.6 5.7 19.7 46.0 Poor 2.2 69.0 17.7 Poor 1.4 80.3 11.3 Poor Poor 11 Inv. ex. 12.2 71.8 10.8 52.1 88.5 Good 11.4 60.6 93.4 Good 10.4 46.5 85.2 Good Good 12 Inv. ex. 11.4 60.6 11.8 66.2 103.5 Good 10.8 52.1 94.7 Good 11.2 57.7 98.2 Good Good 13 Comp. ex. 12 69.0 9.4 32.4 78.3 Good 4.8 32.4 40.0 Poor 2.9 59.2 24.2 Poor Poor 14 Comp. ex. Poor 11.3 59.2 Poor (sliding parts fused) 15 Inv. ex. 11.9 67.6 10.8 52.1 90.8 Good 11.3 59.2 95.0 Good 9.2 29.6 77.3 Good Good 16 Inv. ex. 12.4 74.6 11.4 60.6 91.9 Good 9.7 36.6 78.2 Good 10.1 42.3 81.5 Good Good 17 Inv. ex. 11.6 63.4 12.1 70.4 104.3 Good 10.3 45.1 88.8 Good 9.4 32.4 81.0 Good Good 18 Comp. ex. Poor 12.6 77.5 Poor (sliding parts fused) 19 Comp. ex. Poor Poor (sliding parts fused) 20 Inv. ex. 8.7 22.5 9.1 28.2 104.6 Good 7.9 11.3 90.8 Good 8.2 15.5 94.3 Poor Poor 21 Inv. ex. 9.5 33.8 10.3 45.1 108.4 Good 9.9 39.4 104.2 Good 10.5 47.9 110.5 Poor Poor 21 Inv. ex. 9.5 33.8 10.3 45.1 108.4 Good 9.9 39.4 104.2 Good 10.5 47.9 110.5 Poor Poor 22 Inv. ex 12.7 78.9 12.5 76.1 98.4 Good 11.4 60.6 89.8 Good 11.8 66.2 92.9 Good Good 23 Inv. ex 11.1 56.3 11.3 59.2 101.8 Good 10.1 42.3 91.0 Good 9.4 32.4 84.7 Good Good 24 Inv. ex 9.5 33.8 9.2 29.6 96.8 Good 9.8 38.0 103.2 Good 8.6 21.1 90.5 Good Good 25 Comp. ex. Poor Poor (nugget not formed) 26 Inv. ex 9.2 29.6 8.8 23.9 95.7 Good 9.4 32.4 102.2 Good 8.2 15.5 89.1 Good Good 27 Inv. ex 12.4 74.6 13.1 84.5 105.6 Good 12.6 77.5 101.6 Good 10.1 42.3 81.5 Good Good 28 Inv. ex 12.6 77.5 11.1 56.3 88.1 Good 13.8 94.4 109.5 Good 12.7 78.9 100.8 Good Good 29 Inv. ex 14.4 102.8 13.9 95.8 96.5 Good 14.8 108.5 102.8 Good 9.5 33.8 66.0 Good Good 30 Inv. ex 11.5 62.0 10.2 43.7 88.7 Good 10.9 53.5 94.8 Good 9.4 32.4 81.7 Good Good 31 Inv. ex 10.4 46.5 10.9 53.5 104.8 Good 9.5 33.8 91.3 Good 8.5 19.7 81.7 Good Good 32 Inv. ex 12.3 73.2 11.4 60.6 92.7 Good 11.7 64.8 95.1 Good 10.5 47.9 85.4 Good Good 33 Inv. ex 12.6 77.5 12.1 70.4 96.0 Good 12.4 74.6 98.4 Good 11.6 63.4 92.1 Good Good

INDUSTRIAL APPLICABILITY

(79) The present invention can be utilized for a spot welding electrode used in the past. For this reason, the effect can be enjoyed by application to a conventional apparatus without requiring massive capital investment.

REFERENCE SIGNS LIST

(80) 1. electrode tip 2. electrode support 11. head of electrode tip 13. tail of electrode tip 14. contact-and-conduction part 15. contact-and-conduction surface 16. smallest surrounding circle 19. spring hook for holding electrode tip 22. tail of electrode support 23. head of electrode support 29. spring hook for holding support 31. electrode axis 32. insulating member 39. holding spring 50. steel sheet (welded member) 100. conventional spot welding electrode 101. head of conventional spot welding electrode 102. tail of conventional spot welding electrode 104. contact-and-conduction part of conventional spot welding electrode 105. contact-and-conduction surface of conventional spot welding electrode 131. center axis of conventional spot welding electrode 140. conventional spot welding apparatus