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*Not all tack welds require this amount of energy. Smaller cabled pulse arc attachments can be used for simple tack welds
that require lower energy.
CUSTOM RESISTANCE WELDING TOOLS
It may be helpful to shape the tool for the application. Tools that clamp the parts (e.g. brass lined pliers) should have as
much surface as possible in contact with the part to allow more energy to transfer to the weld location. Remember that
the area between the workpieces should be small to focus the energy if a strong weld is desired. A weldment or bump can
be used to help focus the energy if desired. If you are shaping an electrode to actually perform the weld then the tip should
be as small as is reasonable for the desired weld size (e.g. 1mm spot size or less is typical). Remember that when using an
electrode to perform the welding process, the pressure applied by the electrode tip determines the weld pressure and the
heat generated. A weldment or bump between the two parts to be welded can still be used to focus the energy. Place the
electrode directly over the weldment location (remember the weldment is actually between the two sheets etc, not on the
electrode).
Chapter 3: Tungsten Electrodes
THE SINGLE MOST IMPORTANT VARIABLE IN THE WELDING PROCESS IS THE ELECTRODE. e Orion welder comes
standard with (5) 0.5mm and (5) 1.0mm electrodes. e 1.0mm electrodes are a good all around electrode while the 0.5mm
electrode is excellent for very small projects. e larger 1mm electrode allows more energy to come out at one time. e
smaller 0.5mm electrode is better for applications where less energy is being used.
HANDS ON: Make a weld using 10 Ws and a sharp 1.0mm electrode. Now make a weld using the same settings with a
sharp 0.5mm electrode.
In the ‘HANDS ON’ examples above, more energy was transferred from the Orion into the workpiece for the same setting
using the 1mm electrode. For very small parts, using the small electrode is sufficient. is option reduces the peak weld
current versus using the large electrode and can also allow for a smaller weld spot. For larger parts use the 1mm electrode.
e 1mm electrode is used when needing additional
weld current (more melting for same energy). e larger
electrode is recommended for metals such as silver, due
to higher welding energy requirements of such metals.
*Note: e 0.5mm electrode will “burn” or oxidize at
higher energy settings. As a general suggestion, the 1mm
electrode is a good choice for most applications, even very
small ones
Left: Using too much energy with the 0.5mm electrode will cause it to overheat and reduce its life.
Right: A 1.0mm electrode can weld at a variety of energies without overheating.
Why Use Tungsten Electrodes?
1. Hardness – tungsten is extremely hard and is therefore able to hold its shape during the welding process.
2. Tungsten’s melting temperature is much higher than most other metals. is means the metals being welded will
melt before the tungsten.
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