AWS D8.6:2005

An American National Standard

Specification for Automotive Resistance Spot Welding Electrodes

AWS D8.6: 2005

An American National Standard

Approved by the American National Standards Institute

September 20, 2005

Specification for Automotive Resistance Spot Welding Electrodes

Supersedes AWS D8.6-77

SAE HS-J1156

Prepared by the American Welding Society (AWS) D8 Committee on Automotive Welding

Under the Direction of the AWS Technical Activities Committee

Approved by the AWS Board of Directors

Abstract

This specification outlines the requirements for resistance welding electrodes relating to the automotive welding industry.

550 N.W. LeJeune Road, Miami, FL 33126

International Standard Book Number: 0-87171-008-0

American Welding Society 550 N.W. LeJeune Road, Miami, FL 33126

© 2006 by American Welding Society

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Statement on the Use of American Welding Society Standards

All standards (codes, specifications, recommended practices, methods, classifications, and guides) of the American Welding Society (AWS) are voluntary consensus standards that have been developed in accordance with the rules of the American National Standards Institute (ANSI). When AWS American National Standards are either incorporated in, or made part of, documents that are included in federal or state laws and regulations, or the regulations of other govern- mental bodies, their provisions carry the full legal authority of the statute. In such cases, any changes in those AWS standards must be approved by the governmental body having statutory jurisdiction before they can become a part of those laws and regulations. In all cases, these standards carry the full legal authority of the contract or other document that invokes the AWS standards. Where this contractual relationship exists, changes in or deviations from requirements of an AWS standard must be by agreement between the contracting parties.

AWS American National Standards are developed through a consensus standards development process that brings together volunteers representing varied viewpoints and interests to achieve consensus. While AWS administers the process and establishes rules to promote fairness in the development of consensus, it does not independently test, evaluate, or verify the accuracy of any information or the soundness of any judgments contained in its standards.

AWS disclaims liability for any injury to persons or to property, or other damages of any nature whatsoever, whether special, indirect, consequential or compensatory, directly or indirectly resulting from the publication, use of, or reliance on this standard. AWS also makes no guaranty or warranty as to the accuracy or completeness of any information published herein.

In issuing and making this standard available, AWS is not undertaking to render professional or other services for or on behalf of any person or entity. Nor is AWS undertaking to perform any duty owed by any person or entity to someone else. Anyone using these documents should rely on his or her own independent judgment or, as appropriate, seek the advice of a competent professional in determining the exercise of reasonable care in any given circumstances.

This standard may be superseded by the issuance of new editions. Users should ensure that they have the latest edition.

Publication of this standard does not authorize infringement of any patent or trade name. Users of this standard accept any and all liabilities for infringement of any patent or trade name items. AWS disclaims liability for the infringement of any patent or product trade name resulting from the use of this standard.

Finally, AWS does not monitor, police, or enforce compliance with this standard, nor does it have the power to do so.

On occasion, text, tables, or figures are printed incorrectly, constituting errata. Such errata, when discovered, are posted on the AWS web page (www.aws.org).

Official interpretations of any of the technical requirements of this standard may only be obtained by sending a request, in writing, to the Managing Director, Technical Services Division, American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126 (see Annex H). With regard to technical inquiries made concerning AWS standards, oral opinions on AWS standards may be rendered. However, such opinions represent only the personal opinions of the particular individuals giving them. These individuals do not speak on behalf of AWS, nor do these oral opinions constitute official or unofficial opinions or interpretations of AWS. In addition, oral opinions are informal and should not be used as a substitute for an official interpretation.

This standard is subject to revision at any time by the AWS D8 Committee on Automotive Welding. It must be reviewed every five years, and if not revised, it must be either reaffirmed or withdrawn. Comments (recommendations, additions, or deletions) and any pertinent data that may be of use in improving this standard are required and should be addressed to AWS Headquarters. Such comments will receive careful consideration by the AWS D8 Committee on Automotive Welding and the author of the comments will be informed of the Committee’s response to the comments. Guests are invited to attend all meetings of the AWS D8 Committee on Automotive Welding to express their comments verbally. Procedures for appeal of an adverse decision concerning all such comments are provided in the Rules of Operation of the Technical Activities Committee. A copy of these Rules can be obtained from the American Welding Society, 550

1. LeJeune Road, Miami, FL 33126.

   
   

   
   

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   Personnel

   
   

   AWS D8 Committee on Automotive Welding

   J. C. Bohr, Chair General Motors North America

   W. H. Brafford, 1st Vice Chair Tuffaloy Products

   1. R. Kolodziej, 2nd Vice Chair Ford Motor Company

      1. M. Alonso, Secretary American Welding Society

         1. Armao The Lincoln Electric Company

         2. Armstrong Dynamic Suspension, Division of Multimatic

            J. Dolfi Consultant

            *J. F. Hinrichs Friction Stir Link, Incorporated

            1. H. Lalam Mittal Steel Company

            2. W. Morrissett Consultant

J. S. Noruk Servo Robotic Corporation

J. P. Osborne DeStaCo Industries

M. D. Tumuluru U.S. Steel Corporation

AWS D8D Subcommittee on Automotive Resistance Spot Welding

J. C. Bohr, Chair General Motors North America

1. F. Qualls, 1st Vice Chair Consultant

   1. Zhang, 2nd Vice Chair University of Michigan

      1. M. Alonso, Secretary American Welding Society

         1. Accorsi DaimlerChrysler

W. H. Brafford Tuffaloy Products

T. Coon Ford Motor Company

G. J. Daumeyer Resistance Welders Equipment and Sales Company

D. P. Kelly Fusion Welding Solutions

1. Kimchi Edison Welding Institute

   M. Kuo Mittal Steel Company

   1. P. Lee DOFASCO, Incorporated

T. W. Morrissett Consultant

T. V. Natale A K Steel Corporation

C. J. Orsette RoMan Engineering Services, Incorporated

J. P. Osborne DeStaCo Industries

E. Pakalnins DaimlerChrysler

W. Peterson Edison Welding Institute

N. S. Scotchmer Huys Industries

T. Sparschu Candid Logic/Craftline, Incorporated

M. D. Tumuluru U.S. Steel Corporation

D. J. Walker Centerline (Windsor) Ltd.

AWS Task Force for Document Preparation and Revision

W. H. Brafford Tuffaloy Products

P. Harris Tuffaloy Products

T. W. Morrissett Consultant

C. Padden Ford Motor Company

R. Roberts General Motors Corporation

*Advisor

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Foreword

This foreword is not a part of AWS D8.6:2005, Specification for Automotive Resistance Spot Welding Electrodes, but is included for informational purposes only.

This specification is designed to supplement RWMA Bulletin 16, Resistance Welding Equipment Standards.

Comments and suggestions for the improvement of this standard are welcome. They should be sent to the Secretary, AWS D8 Committee on Automotive Welding, American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126.

Official interpretation of any of the technical requirements of this standard may only be obtained by sending a request, in writing, to the Managing Director, Technical Services Division, American Welding Society. A formal reply will be issued after it has been reviewed by the appropriate personnel following established procedures.

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Table of Contents

Page No.

Personnel v

Foreword vii

Table of Contents ix

List of Tables xi

List of Figures xii

1. Scope 1

2. Normative References 1

3. Terms and Definitions 1

4. Materials 2

   1. Wrought and Forged Materials 2

   2. Material Structure 2

   3. Chemical Composition 2

   4. Physical Requirements 2

5. Dimensions and Specifications 2

   1. Contact Surfaces 2

   2. Water Passages 2

   3. Bent Electrodes 2

6. Identification 2

   1. Markings 2

   2. Electrode Identification Systems for AWS RSW Straight and Bent Electrodes 2

   3. Electrode Identification System for AWS RSW Cap Electrodes 2

   4. Electrode Identification System for AWS RSW Cap-Adaptor Shanks 2

7. RWMA Tapered and Straight Shank Electrodes 2

   1. Standard Tapered Electrodes 2

   2. Standard Straight Electrode Noses 2

8. RWMA Electrode Caps and Cap-Adaptor Shanks 5

   1. Male Cap Electrodes 5

   2. Cap-Adaptor Shanks for Male Cap Electrodes 5

   3. Female Cap Electrodes 5

   4. Cap-Adaptor Shanks for Female Cap Electrodes 5

9. Single-Bend Electrodes 5

   1. Dimensions for Single-Bend Electrodes 5

   2. Dimensions for Water Tubes in Single-Bend Electrodes 5

10. Double-Bend Electrodes 5

    1. Dimensions for Double-Bend Electrodes 5

    2. Dimensions for Water Tubes in Double-Bend Electrodes 5

11. Special-Faced Electrodes 5

12. Single- and Double-Bend Adaptor Shanks for Standard Electrode Caps 5

    1. Single-Bend Adaptor Shanks for Standard Electrode Caps 5

       Page No.

    2. Double-Bend Adaptor Shanks for Standard Electrode Caps 5

13. Engineering Information 5

Annex A (Informative)—Recommended Electrode Materials for Spot Welding Dissimilar and

Similar Metals 31

Annex B (Informative)— Standard Gauges for Confirmation of RWMA “Standard Electrode Tapers” 35

Annex C (Informative)— Standard Gauges for Confirmation of RWMA “Standard Male Cap

Electrode Tapers” 37

Annex D (Informative)—Standard Gauges for Confirmation of RWMA “Standard Female Cap

Electrode Tapers” 39

Annex E (Informative)— Recommended Sizes of Stock RWMA Electrode Numbers and Welding Face

Diameters for Use at Various Welding Force Ranges 41

Annex F (Informative)— Cap Electrodes and Cap Electrode Adaptor Conventions in Common Usage by Automotive Companies 43

Annex G (Informative)—Female Cap Electrodes and Adaptor Conventions in Common Usage by

Automotive Companies 71

Annex H (Informative)—Guidelines for the Preparation of Technical Inquiries 81

List of AWS Documents on Automotive Welding 83

List of Tables

Table Page No.

1. Chemical Compositions of RWMA Materials 3

2. Minimum Mechanical and Physical Properties for RWMA Copper Alloys 4

3. Coding for Standard Straight Electrodes 7

4. Coding for Single-Bend Electrodes 8

5. Coding for Double-Bend Electrodes 9

6. Coding for Standard Male Cap Electrodes 10

7. Coding for Standard Female Cap Electrodes 11

8. Coding for Straight Cap-Adaptor Shanks for Male Electrode Caps 12

9. Coding for Single-Bend Adaptor Shanks for Male Electrode Caps 13

10. Coding for Double-Bend Adaptor Shanks for Male Electrode Caps 14

11. Coding for Straight Cap-Adaptor Shanks for Female Electrode Caps 15

12. Coding for Single-Bend Adaptor Shanks for Female Electrode Caps 16

13. Coding for Double-Bend Adaptor Shanks for Female Electrode Caps 17

14. Standard Dimensions for Straight Electrodes, Tapers, and Water Holes 18

15. Standard Dimensions for Standard Straight Electrode Noses 20

16. Standard Dimensions for Male Cap Electrodes 21

17. Standard Dimensions for Straight Cap-Adaptor Shanks for Male Cap Electrodes 23

18. Standard Dimensions for Female Cap Electrodes 25

19. Standard Dimensions for Straight Cap-Adaptor Shanks for Female Cap Electrodes 27

20. Water Tube Specifications for Tubes Inserted in Single- and Double-Bend Electrodes

    (not part of RWMA standards) 29

21. Double-Bend Electrodes Listed by the RWMA 29

1. Standard for Male Cap Electrodes 47

   F.1M Standard for Male Cap Electrodes 47

2. Standard for Male Cap Electrode and Adaptor Shank 54

   F.2M Standard for Male Cap Electrode and Adaptor Shank 55

3. Standard for Increased Water Flow Male Cap Electrodes 63

   F.3M Standard for Increased Water Flow Male Cap Electrodes 63

4. Standard for Female Cap Electrodes 67

   F.4M Standard for Female Cap Electrodes 67

5. Standard for Straight Adaptors for Type “F” Female Cap Electrodes 70

1. 5M Standard for Straight Adaptors for Type “F” Female Cap Electrodes 70

   1. Standard for Straight Adaptor for Female Cap Electrodes 74

2. 1M Standard for Straight Adaptor for Female Cap Electrodes 74

1. Standard for Straight Adaptors for RWMA #4 Female Cap Electrodes and #1 Special Tapers 76

   G.2M Standard for Straight Adaptors for RWMA #4 Female Cap Electrodes and #1 Special Tapers 76

2. Standard for Straight Adapters for RWMA #6 Female Cap Electrodes 78

1. 3M Standard for Straight Adapters for RWMA #6 Female Cap Electrodes 78

   
   

   List of Figures

   
   

   Figure Page No.

   1. Electrode Types 7

   2. Single-Bend Electrode Terminology 8

   3. Double-Bend Electrode Terminology. 9

   4. Male Cap Electrode Types. 10

   5. Female Cap Electrode Types 11

   6. Straight Cap-Adaptor Shank for Male Cap 12

   7. Single-Bend Cap-Adaptor Shank for Male Cap 13

   8. Double-Bend Cap-Adaptor Shank for Male Cap. 14

   9. Straight Cap-Adaptor Shank for Female Cap 15

   10. Single-Bend Cap-Adaptor Shank for Female Cap 16

   11. Double-Bend Cap-Adaptor Shank for Female Cap 17

   12. Standard for Straight Electrodes 19

   13. Nose Configurations for Standard Straight Electrodes 20

   14. Standard Male Cap Electrodes. 22

   15. Cap-Adaptor Shanks for Male Cap Electrodes 24

   16. Standard Female Cap Electrodes 26

   17. Cap-Adaptor Shanks for Female Cap Electrodes 28

1. Male Cap Electrodes—Ordering Codes 44

   F1.M Male Cap Electrodes—Ordering Codes 45

2. Male Cap Electrode Dimensions 46

   F.2M Male Cap Electrode Dimensions 46

3. Male Cap Electrode Nose Descriptions 48

   F.3M Male Cap Electrode Nose Descriptions 49

4. Male Cap Electrode Adaptor Shanks—Ordering Codes 50

   F.4M Male Cap Electrode Adaptor Shanks—Ordering Codes 51

5. Male Cap Electrode Adaptor Shanks—Dimensional Specifications 52

   F.5M Male Cap Electrode Adaptor Shanks—Dimensional Specifications 53

6. 3/4 in Increased Water Flow Male Cap Electrodes—Ordering Codes 57

   F.6M 19 mm Increased Water Flow Male Cap Electrodes—Ordering Codes 59

7. 3/4 in Increased Water Flow Male Cap Electrodes—Nose Design 60

   F.7M 19 mm Increased Water Flow Male Cap Electrodes—Nose Design 61

8. 3/4 in Increased Water Flow Male Cap Electrodes—Dimensions 62

   F.8M 19 mm Increased Water Flow Male Cap Electrodes—Dimensions 62

9. Type “F” Female Cap Electrodes—Ordering Codes 64

10. Type “F” Female Cap Electrodes—Description 65

    F.10M Type “F” Female Cap Electrodes—Description 66

11. Straight Adaptor for Type “F” Female Cap Electrodes—Ordering Codes 68

12. Straight Adaptor for Type “F” Female Cap Electrodes—Description 69

1. 2M Straight Adaptor for Type “F” Female Cap Electrodes—Description 69

   1. Nomenclature for Straight Adaptors and Assemblies for Female Cap Electrodes with

      RWMA #5 Taper 72

2. 1M Nomenclature for Straight Adaptors and Assemblies for Female Cap Electrodes with

RWMA #5 Taper 73

1. Nomenclature for Straight Adaptors and Assemblies for Female Cap Electrodes with

   RWMA #4 Cap and RWMA #4 Tapers 75

   Figure Page No.

   G.2M Nomenclature for Straight Adaptors and Assemblies for Female Cap Electrodes with

   RWMA #4 Cap and RWMA #4 Tapers 75

2. Nomenclature for Straight Adaptors and Caps for Female Cap Electrodes with RWMA #6 Taper 77

   G.3M Nomenclature for Straight Adaptors and Caps for Female Cap Electrodes with RWMA #6 Taper 77

3. Nomenclature for Female Electrode Caps 79

G.4M Nomenclature for Female Electrode Caps 80

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Specification for Automotive Resistance Spot Welding Electrodes

1. Scope

   This specification outlines the requirements for resistance spot welding electrodes, hereafter referred to as AWS RSW electrodes or simply RSW electrodes.

   RSW electrodes shall comply with Resistance Welder Manufacturers’ Association (RWMA) standards in addi- tion to the specifications and requirements of this specifi- cation. In case of any conflict between RWMA standards and AWS standards, the AWS specification shall govern. Examples of several widely used commercially available standard automotive industrial type caps and shanks are shown in the informative annexes.

   This specification makes sole use of U.S. Customary Units. Approximate mathematical equivalents in the International System of Units (SI) are provided for com- parison in parentheses or in appropriate columns in tables and figures.

   Safety and health issues and concerns are beyond the scope of this specification, and therefore are not fully addressed herein. Safety and health information is avail- able from other sources, including, but not limited to, ANSI Z49.1, Safety in Welding, Cutting, and Allied Processes, and applicable federal and state regulations.

   
   

2. Normative References

   The following standard contains provisions which, through reference in this text, constitute provisions of this AWS standard. For undated references, the latest edition of the referenced standard shall apply. For dated references, subsequent amendments to, or revisions of, any of these publications do not apply.

   1. RWMA Bulletin 16, Resistance Welding Equipment Standards, Section 11; and

      
      

   2. AWS A3.0, Standard Welding Terms and Defini- tions Including Terms for Adhesive Bonding, Brazing, Soldering, Thermal Cutting, and Thermal Spraying.2

1. Terms and Definitions

   The definitions given here are the names and descrip- tions of the various types, shapes, and configurations used to identify resistance spot welding electrodes. All other terms used herein are defined by AWS A3.0, Stan- dard Welding Terms and Definitions.

   For the purposes of this document, the following terms and definitions apply:

   resistance spot welding (RSW) electrodes. The compo- nent of a resistance welding machine through which the welding current and, in most cases, pressure are applied directly to the work.

   electrode shapes. The various forms of RSW electrodes covered by this standard are as follows:

   1. Straight electrodes with tapered shanks

   2. Straight electrodes with straight shanks

   3. Electrode caps and cap-adaptor shanks

   4. Single-bend electrodes

   5. Double-bend electrodes

   6. Special-faced electrodes

The RSW electrode tapers and straight shanks are shown and defined in Figure 12 (see Clause 7) of this specification.

nose configurations. The following nose styles are shown and defined in Figure 13 (see 7.2) of this specification.

1. Type A—Pointed

1 RWMA standards are published by the American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126.

2 AWS standards are published by the American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126.