Specification for Automotive Resistance Spot Welding ...

Specification forAutomotiveResistance SpotWelding Electrodes

AWS D8.6:2005An American National Standard

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

AWS D8.6:2005An American National Standard

Approved by theAmerican National Standards Institute

September 20, 2005

Specification for

Automotive Resistance

Spot Welding Electrodes

Supersedes AWS D8.6-77SAE HS-J1156

Prepared by theAmerican Welding Society (AWS) D8 Committee on Automotive Welding

Under the Direction of theAWS Technical Activities Committee

Approved by theAWS Board of Directors

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

AWS D8.6:2005

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International Standard Book Number: 0-87171-008-0American Welding Society

550 N.W. LeJeune Road, Miami, FL 33126© 2006 by American Welding Society

All rights reservedPrinted in the United States of America

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Authorization to photocopy items for internal, personal, or educational classroom use only or the internal, personal, oreducational classroom use only of specific clients is granted by the American Welding Society provided that the appropriatefee is paid to the Copyright Clearance Center, 222 Rosewood Drive, Danvers, MA 01923, tel: (978) 750-8400; Internet:<www.copyright.com>.

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AWS D8.6:2005

Statement on the Use of American Welding Society Standards

All standards (codes, specifications, recommended practices, methods, classifications, and guides) of the AmericanWelding Society (AWS) are voluntary consensus standards that have been developed in accordance with the rules of theAmerican National Standards Institute (ANSI). When AWS American National Standards are either incorporated in, ormade 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 AWSstandards must be approved by the governmental body having statutory jurisdiction before they can become a part ofthose laws and regulations. In all cases, these standards carry the full legal authority of the contract or other documentthat invokes the AWS standards. Where this contractual relationship exists, changes in or deviations from requirementsof an AWS standard must be by agreement between the contracting parties.

AWS American National Standards are developed through a consensus standards development process that bringstogether volunteers representing varied viewpoints and interests to achieve consensus. While AWS administers the processand establishes rules to promote fairness in the development of consensus, it does not independently test, evaluate, orverify 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, whetherspecial, indirect, consequential or compensatory, directly or indirectly resulting from the publication, use of, or relianceon this standard. AWS also makes no guaranty or warranty as to the accuracy or completeness of any informationpublished herein.

In issuing and making this standard available, AWS is not undertaking to render professional or other services for or onbehalf of any person or entity. Nor is AWS undertaking to perform any duty owed by any person or entity to someoneelse. Anyone using these documents should rely on his or her own independent judgment or, as appropriate, seek theadvice 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 acceptany and all liabilities for infringement of any patent or trade name items. AWS disclaims liability for the infringement ofany 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 postedon 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 opinionson AWS standards may be rendered. However, such opinions represent only the personal opinions of the particularindividuals giving them. These individuals do not speak on behalf of AWS, nor do these oral opinions constitute officialor unofficial opinions or interpretations of AWS. In addition, oral opinions are informal and should not be used as asubstitute for an official interpretation.

This standard is subject to revision at any time by the AWS D8 Committee on Automotive Welding. It must be reviewedevery 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 addressedto AWS Headquarters. Such comments will receive careful consideration by the AWS D8 Committee on AutomotiveWelding and the author of the comments will be informed of the Committee’s response to the comments. Guests areinvited 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 ofthe Technical Activities Committee. A copy of these Rules can be obtained from the American Welding Society, 550N.W. LeJeune Road, Miami, FL 33126.

This page is intentionally blank.

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AWS D8.6:2005

Personnel

*Advisor

AWS D8 Committee on Automotive Welding

J. C. Bohr, Chair General Motors North AmericaW. H. Brafford, 1st Vice Chair Tuffaloy Products

D. R. Kolodziej, 2nd Vice Chair Ford Motor CompanyA. M. Alonso, Secretary American Welding Society

F. Armao The Lincoln Electric CompanyG. Armstrong Dynamic Suspension, Division of Multimatic

J. Dolfi Consultant*J. F. Hinrichs Friction Stir Link, Incorporated

S. H. Lalam Mittal Steel CompanyT. W. Morrissett Consultant

J. S. Noruk Servo Robotic CorporationJ. 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 AmericaW. F. Qualls, 1st Vice Chair Consultant

H. Zhang, 2nd Vice Chair University of MichiganA. M. Alonso, Secretary American Welding Society

I. Accorsi DaimlerChryslerW. H. Brafford Tuffaloy Products

T. Coon Ford Motor CompanyG. J. Daumeyer Resistance Welders Equipment and Sales Company

D. P. Kelly Fusion Welding SolutionsM. Kimchi Edison Welding Institute

M. Kuo Mittal Steel CompanyA. P. Lee DOFASCO, Incorporated

T. W. Morrissett ConsultantT. V. Natale A K Steel CorporationC. J. Orsette RoMan Engineering Services, Incorporated

J. P. Osborne DeStaCo IndustriesE. Pakalnins DaimlerChryslerW. Peterson Edison Welding Institute

N. S. Scotchmer Huys IndustriesT. Sparschu Candid Logic/Craftline, Incorporated

M. D. Tumuluru U.S. Steel CorporationD. J. Walker Centerline (Windsor) Ltd.

AWS Task Force for Document Preparation and Revision

W. H. Brafford Tuffaloy ProductsP. Harris Tuffaloy Products

T. W. Morrissett ConsultantC. Padden Ford Motor CompanyR. Roberts General Motors Corporation


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AWS D8.6:2005

Foreword

This foreword is not a part of AWS D8.6:2005, Specification for Automotive ResistanceSpot 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, inwriting, to the Managing Director, Technical Services Division, American Welding Society. A formal reply will beissued after it has been reviewed by the appropriate personnel following established procedures.


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Table of Contents

Page No.

Personnel ......................................................................................................................................................................vForeword ....................................................................................................................................................................viiTable of Contents.........................................................................................................................................................ixList of Tables ...............................................................................................................................................................xiList of Figures.............................................................................................................................................................xii

1. Scope .....................................................................................................................................................................1

2. Normative References .........................................................................................................................................1

3. Terms and Definitions.........................................................................................................................................1

4. Materials ..............................................................................................................................................................24.1 Wrought and Forged Materials....................................................................................................................24.2 Material Structure ........................................................................................................................................24.3 Chemical Composition ................................................................................................................................24.4 Physical Requirements.................................................................................................................................2

5. Dimensions and Specifications ...........................................................................................................................25.1 Contact Surfaces ..........................................................................................................................................25.2 Water Passages ............................................................................................................................................25.3 Bent Electrodes............................................................................................................................................2

6. Identification........................................................................................................................................................26.1 Markings ......................................................................................................................................................26.2 Electrode Identification Systems for AWS RSW Straight and Bent Electrodes .........................................26.3 Electrode Identification System for AWS RSW Cap Electrodes ................................................................26.4 Electrode Identification System for AWS RSW Cap-Adaptor Shanks .......................................................2

7. RWMA Tapered and Straight Shank Electrodes.............................................................................................27.1 Standard Tapered Electrodes .......................................................................................................................27.2 Standard Straight Electrode Noses ..............................................................................................................2

8. RWMA Electrode Caps and Cap-Adaptor Shanks .........................................................................................58.1 Male Cap Electrodes....................................................................................................................................58.2 Cap-Adaptor Shanks for Male Cap Electrodes............................................................................................58.3 Female Cap Electrodes ................................................................................................................................58.4 Cap-Adaptor Shanks for Female Cap Electrodes ........................................................................................5

9. Single-Bend Electrodes .......................................................................................................................................59.1 Dimensions for Single-Bend Electrodes......................................................................................................59.2 Dimensions for Water Tubes in Single-Bend Electrodes ............................................................................5

10. Double-Bend Electrodes .....................................................................................................................................510.1 Dimensions for Double-Bend Electrodes ....................................................................................................510.2 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 .....................................................512.1 Single-Bend Adaptor Shanks for Standard Electrode Caps ........................................................................5

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

13. Engineering Information ....................................................................................................................................5

Annex A (Informative)—Recommended Electrode Materials for Spot Welding Dissimilar andSimilar Metals ...................................................................................................................31

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

Electrode Tapers”..............................................................................................................37Annex D (Informative)—Standard Gauges for Confirmation of RWMA “Standard Female Cap

Electrode Tapers”..............................................................................................................39Annex E (Informative)— Recommended Sizes of Stock RWMA Electrode Numbers and Welding Face

Diameters for Use at Various Welding Force Ranges ......................................................41Annex F (Informative)— Cap Electrodes and Cap Electrode Adaptor Conventions in Common Usage by

Automotive Companies.....................................................................................................43Annex G (Informative)—Female Cap Electrodes and Adaptor Conventions in Common Usage by

Automotive Companies.....................................................................................................71Annex H (Informative)—Guidelines for the Preparation of Technical Inquiries ......................................................81

List of AWS Documents on Automotive Welding.....................................................................................................83

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List of Tables

Table Page No.

1 Chemical Compositions of RWMA Materials...............................................................................................32 Minimum Mechanical and Physical Properties for RWMA Copper Alloys .................................................43 Coding for Standard Straight Electrodes .......................................................................................................74 Coding for Single-Bend Electrodes ...............................................................................................................85 Coding for Double-Bend Electrodes..............................................................................................................96 Coding for Standard Male Cap Electrodes ..................................................................................................107 Coding for Standard Female Cap Electrodes ...............................................................................................118 Coding for Straight Cap-Adaptor Shanks for Male Electrode Caps ............................................................129 Coding for Single-Bend Adaptor Shanks for Male Electrode Caps ............................................................13

10 Coding for Double-Bend Adaptor Shanks for Male Electrode Caps...........................................................1411 Coding for Straight Cap-Adaptor Shanks for Female Electrode Caps ........................................................1512 Coding for Single-Bend Adaptor Shanks for Female Electrode Caps.........................................................1613 Coding for Double-Bend Adaptor Shanks for Female Electrode Caps .......................................................1714 Standard Dimensions for Straight Electrodes, Tapers, and Water Holes ....................................................1815 Standard Dimensions for Standard Straight Electrode Noses......................................................................2016 Standard Dimensions for Male Cap Electrodes ...........................................................................................2117 Standard Dimensions for Straight Cap-Adaptor Shanks for Male Cap Electrodes .....................................2318 Standard Dimensions for Female Cap Electrodes........................................................................................2519 Standard Dimensions for Straight Cap-Adaptor Shanks for Female Cap Electrodes..................................2720 Water Tube Specifications for Tubes Inserted in Single- and Double-Bend Electrodes

(not part of RWMA standards) ....................................................................................................................2921 Double-Bend Electrodes Listed by the RWMA ..........................................................................................29F.1 Standard for Male Cap Electrodes ...............................................................................................................47F.1M Standard for Male Cap Electrodes ...............................................................................................................47F.2 Standard for Male Cap Electrode and Adaptor Shank.................................................................................54F.2M Standard for Male Cap Electrode and Adaptor Shank.................................................................................55F.3 Standard for Increased Water Flow Male Cap Electrodes ...........................................................................63F.3M Standard for Increased Water Flow Male Cap Electrodes ...........................................................................63F.4 Standard for Female Cap Electrodes............................................................................................................67F.4M Standard for Female Cap Electrodes............................................................................................................67F.5 Standard for Straight Adaptors for Type “F” Female Cap Electrodes.........................................................70F.5M Standard for Straight Adaptors for Type “F” Female Cap Electrodes.........................................................70G.1 Standard for Straight Adaptor for Female Cap Electrodes ..........................................................................74G.1M Standard for Straight Adaptor for Female Cap Electrodes ..........................................................................74G.2 Standard for Straight Adaptors for RWMA #4 Female Cap Electrodes and #1 Special Tapers .................76G.2M Standard for Straight Adaptors for RWMA #4 Female Cap Electrodes and #1 Special Tapers .................76G.3 Standard for Straight Adapters for RWMA #6 Female Cap Electrodes ......................................................78G.3M Standard for Straight Adapters for RWMA #6 Female Cap Electrodes ......................................................78

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List of Figures

Figure Page No.

1 Electrode Types ...........................................................................................................................................72 Single-Bend Electrode Terminology ...........................................................................................................83 Double-Bend Electrode Terminology..........................................................................................................94 Male Cap Electrode Types.........................................................................................................................105 Female Cap Electrode Types .....................................................................................................................116 Straight Cap-Adaptor Shank for Male Cap ...............................................................................................127 Single-Bend Cap-Adaptor Shank for Male Cap ........................................................................................138 Double-Bend Cap-Adaptor Shank for Male Cap.......................................................................................149 Straight Cap-Adaptor Shank for Female Cap............................................................................................15

10 Single-Bend Cap-Adaptor Shank for Female Cap.....................................................................................1611 Double-Bend Cap-Adaptor Shank for Female Cap ...................................................................................1712 Standard for Straight Electrodes................................................................................................................1913 Nose Configurations for Standard Straight Electrodes..............................................................................2014 Standard Male Cap Electrodes...................................................................................................................2215 Cap-Adaptor Shanks for Male Cap Electrodes..........................................................................................2416 Standard Female Cap Electrodes ...............................................................................................................2617 Cap-Adaptor Shanks for Female Cap Electrodes ......................................................................................28F.1 Male Cap Electrodes—Ordering Codes ....................................................................................................44F1.M Male Cap Electrodes—Ordering Codes ....................................................................................................45F.2 Male Cap Electrode Dimensions ...............................................................................................................46F.2M Male Cap Electrode Dimensions ...............................................................................................................46F.3 Male Cap Electrode Nose Descriptions.....................................................................................................48F.3M Male Cap Electrode Nose Descriptions.....................................................................................................49F.4 Male Cap Electrode Adaptor Shanks—Ordering Codes ...........................................................................50F.4M Male Cap Electrode Adaptor Shanks—Ordering Codes ...........................................................................51F.5 Male Cap Electrode Adaptor Shanks—Dimensional Specifications.........................................................52F.5M Male Cap Electrode Adaptor Shanks—Dimensional Specifications.........................................................53F.6 3/4 in Increased Water Flow Male Cap Electrodes—Ordering Codes......................................................57F.6M 19 mm Increased Water Flow Male Cap Electrodes—Ordering Codes....................................................59F.7 3/4 in Increased Water Flow Male Cap Electrodes—Nose Design...........................................................60F.7M 19 mm Increased Water Flow Male Cap Electrodes—Nose Design.........................................................61F.8 3/4 in Increased Water Flow Male Cap Electrodes—Dimensions ............................................................62F.8M 19 mm Increased Water Flow Male Cap Electrodes—Dimensions ..........................................................62F.9 Type “F” Female Cap Electrodes—Ordering Codes.................................................................................64F.10 Type “F” Female Cap Electrodes—Description........................................................................................65F.10M Type “F” Female Cap Electrodes—Description........................................................................................66F.11 Straight Adaptor for Type “F” Female Cap Electrodes—Ordering Codes ...............................................68F.12 Straight Adaptor for Type “F” Female Cap Electrodes—Description ......................................................69F.12M Straight Adaptor for Type “F” Female Cap Electrodes—Description ......................................................69G.1 Nomenclature for Straight Adaptors and Assemblies for Female Cap Electrodes with

RWMA #5 Taper .......................................................................................................................................72G.1M Nomenclature for Straight Adaptors and Assemblies for Female Cap Electrodes with

RWMA #5 Taper .......................................................................................................................................73G.2 Nomenclature for Straight Adaptors and Assemblies for Female Cap Electrodes with

RWMA #4 Cap and RWMA #4 Tapers ....................................................................................................75

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G.2M Nomenclature for Straight Adaptors and Assemblies for Female Cap Electrodes withRWMA #4 Cap and RWMA #4 Tapers ....................................................................................................75

G.3 Nomenclature for Straight Adaptors and Caps for Female Cap Electrodes with RWMA #6 Taper.........77G.3M Nomenclature for Straight Adaptors and Caps for Female Cap Electrodes with RWMA #6 Taper.........77G.4 Nomenclature for Female Electrode Caps.................................................................................................79G.4M Nomenclature for Female Electrode Caps.................................................................................................80


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AWS D8.6:2005

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1. ScopeThis specification outlines the requirements for resistancespot welding electrodes, hereafter referred to as AWSRSW electrodes or simply RSW electrodes.

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

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

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

2. Normative ReferencesThe following standard contains provisions which,through reference in this text, constitute provisions ofthis AWS standard. For undated references, the latestedition of the referenced standard shall apply. For datedreferences, subsequent amendments to, or revisions of,any of these publications do not apply.

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

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

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

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

For the purposes of this document, the following termsand definitions apply:

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

electrode shapes. The various forms of RSW electrodescovered 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 areshown and defined in Figure 12 (see Clause 7) of thisspecification.

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

1. Type A—Pointed

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

Specification for AutomotiveResistance Spot Welding Electrodes

AWS D8.6:2005

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2. Type B—Dome

3. Type C—Flat

4. Type D—Offset

5. Type E—Truncated cone

6. Type F—Radius

4. Materials4.1 Wrought and Forged Materials. Only wrought andforged copper alloys are considered standard under thisspecification, excluding the special face materials.

4.2 Material Structure. The material shall be of uniformhomogenous structure, free from irregularities in surfacehardness, segregation, oxides, or harmful inclusions.

4.3 Chemical Composition. The approximate chemicalcompositions of the electrode material shall be as shownin Table 1.

4.4 Physical Requirements. The physical requirementsfor various electrode materials are given in Table 2.

5. Dimensions and Specifications5.1 Contact Surfaces. All contact surfaces shall besmooth, 35 µin (0.88 µm) maximum, and free of toolmarks for good electrical contact.

5.2 Water Passages. When pointed drills are used forwater passages, the drill point shall have a 120° includedangle.

5.3 Bent Electrodes. All bent electrodes shall have aminimum bend radius of 3/8 in on 1/2 in (9.5 mm on12.7 mm) diameter electrodes, 1/2 in on 5/8 in (12.7 mmon 15.9 mm) diameter electrodes, and 5/8 in on 3/4 in(15.9 mm on 19 mm) diameter electrodes.

6. Identification6.1 Markings. All electrodes shall be clearly markedwith the vendor’s name and the RSW standard number.

Note: Do not mark on the mechanical or electrical con-tact surfaces. Etching is not acceptable.

6.2 Electrode Identification Systems for AWS RSWStraight and Bent Electrodes. The following identifica-tion system shall be used for the AWS RSW straight andbent electrodes:

6.2.1 Codes for RWMA standard straight electrodesare shown in Table 3 and Figure 1.

6.2.2 Codes for RWMA single-bend electrodes areshown in Table 4 and Figure 2.

6.2.3 Codes for RWMA double-bend electrodes areshown in Table 5 and Figure 3.

6.3 Electrode Identification System for AWS RSWCap Electrodes. The following identification systemwill be used for AWS RSW cap electrodes:

6.3.1 Codes for RWMA standard male cap electrodesare shown in Table 6 and Figure 4.

6.3.2 Codes for RWMA standard female cap elec-trodes are shown in Table 7 and Figure 5.

6.4 Electrode Identification System for AWS RSWCap-Adaptor Shanks. The following identification sys-tem will be used for standard RSW cap-adaptor shanks:

6.4.1 Codes for RWMA straight cap-adaptor shanksfor male caps are shown in Table 8 and Figure 6.

6.4.2 Codes for RWMA single-bend cap-adaptorshanks for male caps are shown in Table 9 and Figure 7.

6.4.3 Codes for RWMA double-bend cap-adaptorshanks for male caps are shown in Table 10 and Figure 8.

6.4.4 Codes for RWMA straight cap-adaptor shanksfor female caps are shown in Table 11 and Figure 9.

6.4.5 Codes for RWMA single-bend cap-adaptorshanks for female caps are shown in Table 12 and Figure10.

6.4.6 Codes for RWMA double-bend cap-adaptorshanks for female caps are shown in Table 13 and Figure11.

7. RWMA Tapered and Straight Shank Electrodes

The term “straight shank” should not be confused with“cap-adaptor shank.” Most standard electrodes are de-signed with “tapers” to fit standard holders. “Straightshank” electrodes are rare, and refer to those made with-out tapers. No tables or figures are provided for theseitems. Dimensions “J” and “K” will match dimension“M” for any “straight shank electrode.”

7.1 Standard Tapered Electrodes. The general dimen-sions for RSW tapered electrodes shall be as shown inTable 14 and Figure 12.

7.2 Standard Straight Electrode Noses. The nose con-figurations for RWMA RSW Electrodes shall be asshown in Table 15 and Figure 13.

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Table 1Chemical Compositionsa of RWMA Materials

RWMA Class

RWMA Number Description

Cu(incl. Ag) Fe W Cd Ni Co Cr Si Be Pb Zr Al

Group A—Copper Base Alloys

1 1.15000b Zirconium Copper

99.80 Min.

0.7–1.20

0.10–0.200

1 1.16200b Cadmium Copper

Rem. 0.02 Max.

2 2.18150b Chromium-Zirconium Copper

Rem. 0.5–1.50

0.05–0.250

2 2.18200b Chromium Copper

Rem. 0.10 Max.

0.6–1.20

0.10 Max.

0.05 Max.

3 3.17500b Cobalt-Beryllium Copper

Rem. 0.10 Max.

2.4–2.70

0.20 Max.

0.4–0.70

0.20 Max.

3 3.17510b Nickel-Beryllium Copper

Rem. 0.10 Max.

1.4–2.20

0.30 Max.

0.20 Max.

0.2–0.60

0.20 Max.

3 1.18000b Nickel-Silicon-Chromium Copper

Rem. 0.15 Max.

1.8–3.00

0.1–0.80

0.4–0.80

4 4.17200b Beryllium Copper

Rem. 0.02 Max.

0.20 Max.

Group B—Refractory Metal and Refractory Metal Composites

10 10.74450a Copper Tungsten

43–47 Rem.

11 11.74400a Copper Tungsten (ASTM B 702 C1 D)

23–27 Rem.

12 12.74350a Copper Tungsten (ASTM B 702 C1 E)

18–22 Rem.

13 13.74300a Tungsten 99.9 Min.

14 14.42300a Molybdenum (ASTM B 387) Alloy 360 or 361

Mo 99.9 Min.

Group C—Specialty Materials

20 20.15760a Dispersion Strengthened Copper

98.77 0.01 Max.

0.01 Max.

0.58–0.620

a Composition by weight %.b Last five digits of RWMA numbers correspond to five digits following a “C” in the Copper Development Association and Unified Numbering Systems.

Source: RWMA Bulletin 16, Resistance Welding Equipment Standards, Table 1.8.12, January 1996.

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Table 2Minimum Mechanical and Physical Properties for RWMA Copper Alloys

Group Aa

Copper Base Alloys Hardness RockwellConductivity

%IACSb

Yield Strength,cksi

(5% Ext.Under Load)

UltimateTensile Strength,

ksi

Elongation %in 2 in or

4 Diameters

Size Range Class Class Class Class Class

in mm 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3

Diameter—Round Rod Stock (Cold Worked)

Up to1

Up to25

65 HRB 75 HRB 90 HRB 80% 75% 45% 45 55 90 60 65 95 13% 13% 9%

Over 1to 2

Over 25to 51

60 HRB 70 HRB 90 HRB 80% 75% 45% 45 55 90 55 59 92 14% 13% 9%

Over 2to 3

Over 51to 76

55 HRB 65 HRB 90 HRB 80% 75% 45% 45 55 90 50 55 88 15% 13% 9%

Thickness—Square, Rectangular, and Hexagonal Bar Stock (Cold Worked)

Up to1

Up to25

55 HRB 70 HRB 90 HRB 80% 75% 45% 45 45 90 60 65 95 13% 13% 9%

Over1

Over25

50 HRB 65 HRB 90 HRB 80% 75% 45% 45 40 90 50 55 90 14% 13% 9%

Thickness—Forgings

Up to1

Up to25

55 HRB 65 HRB d90 HRBd 80% 75% 45% 45 45 50 60 55 94 12% 13% 9%

Over 1to 2

Over 25to 51

50 HRB 65 HRB d90 HRBd 80% 75% 45% 45 45 50 50 55 90 13% 13% 9%

Over2

Over 51 50 HRB 65 HRB d90 HRBd 80% 75% 45% 45 40 50 50 55 88 13% 13% 9%

Castings

All All NA 55 HRB 90 HRB NA 70% 45% NA 20 45 NA 45 75 NA 12% 5%

a All materials are in fully heat treated condition unless otherwise specified. Round rod up to 1 in (25 mm) diameter is fully heat treated and coldworked.

b Conductivity = where: Conductivity is expressed in %IACS and resistivity is in the units µΩ cm.

c Yield strength listed is typical—actual can be higher or lower.d Hot worked and heat treated—but not cold worked.

Source: Adapted from RWMA Bulletin 16, Resistance Welding Equipment Standards, Table 1.8.4, January 1996.

10.0058 (Resistivity)

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8. RWMA Electrode Caps andCap-Adaptor Shanks

8.1 Male Cap Electrodes. The dimensions for RWMARSW male electrode caps shall be as shown in Table 16and Figure 14.

8.2 Cap-Adaptor Shanks for Male Cap Electrodes.The dimensions for RWMA RSW cap-adaptor shanksfor male cap electrodes shall be as shown in Table 17 andFigure 15.

8.3 Female Cap Electrodes. The dimensions forRWMA RSW female electrode caps shall be as shown inTable 18 and Figure 16.

8.4 Cap-Adaptor Shanks for Female Cap Electrodes.The dimensions for RWMA RSW cap-adaptor shanksfor female cap electrodes are shown in Table 19 andFigure 17.

9. Single-Bend Electrodes9.1 Dimensions for Single-Bend Electrodes. Thedimensions for RWMA RSW single-bend electrodes areshown in Figure 2 (see 6.2.2), with tapers conforming toTable 14 and Figure 12 (see 7.1), and noses conformingto Table 15 and Figure 13 (see 7.2).

9.2 Dimensions for Water Tubes in Single-Bend Elec-trodes. RWMA single-bend electrodes shall be suppliedwith water tubes preinserted. Dimensions for water tubesare given in Table 20.

10. Double-Bend Electrodes10.1 Dimensions for Double-Bend Electrodes. Thedimensions for RWMA RSW double-bend electrodes areshown in Figure 3 (see 6.2.3), with tapers conforming toTable 14 and Figure 12 (see 7.1), and noses conformingto Table 15 and Figure 13 (see 7.2). Table 21 gives com-monly available double-bend electrode designations aslisted by the RWMA.

10.2 Dimensions for Water Tubes in Double-BendElectrodes. RWMA RSW double-bend electrodes shallbe supplied with water tubes preinserted. Dimensions forthe water tubes are given in Table 20 (see 9.2).

11. Special-Faced ElectrodesThe nose portions of standard electrodes may be suppliedwith special faces of refractory metal compositions.Standard nose forms are shown in Table 15 and Figure

13. RWMA standard face materials are shown in Table1, Group B.

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

12.1 Single-Bend Adaptor Shanks for StandardElectrode Caps

12.1.1 The general dimensions for RWMA RSWsingle-bend adaptor shanks for male electrode caps areshown in Figure 7 (see 6.4.2), with taper details con-forming to Table 18 and Figure 15 (see 8.2).

12.1.2 The general dimensions for RWMA RSWsingle-bend adaptor shanks for female electrode caps areshown in Figure 10 (see 6.4.5), with taper details con-forming to Table 19 and Figure 17 (see 8.4).

12.1.3 Single-bend adaptor shanks shall be suppliedwith water tubes preinserted. Dimensions for the watertubes are given in Table 20 (see 9.2).

12.2 Double-Bend Adaptor Shanks for StandardElectrode Caps

12.2.1 The general dimensions for RWMA RSWdouble-bend adaptor shanks for male electrode caps areshown in Figure 8 (see 6.4.3), with taper details con-forming to Table 17 and Figure 15 (see 8.2).

12.2.2 The general dimension for RWMA RSWdouble-bend adaptor shanks for female electrode caps areshown in Figure 11 (see 6.4.6), with taper details con-forming to Table 18 and Figure 16 (see 8.3).

12.2.3 Double-bend adaptor shanks shall be suppliedwith water tubes preinserted. Dimensions for the watertubes are given in Table 20 (see 9.2).

13. Engineering InformationSeveral tables and figures have been placed into theannexes of this specification. This, while very useful, isto be considered informational only, and does not implyany requirements of this standard.

Included are:

Annex A—Recommended Electrode Materials for SpotWelding Dissimilar and Similar Metals

Annex B—Standard Gauges for Confirmation ofRWMA “Standard Electrode Tapers”

Annex C—Standard Gauges for Confirmation ofRWMA “Standard Male Cap Electrode Tapers”

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Annex D—Standard Gauges for Confirmation ofRWMA “Standard Female Cap Electrode Tapers”

Annex E—Recommended Sizes of Stock RWMA Elec-trode Numbers and Welding Face Diameters for use atVarious Welding Force Ranges

Annex F—Cap Electrode and Cap Electrode Adaptor Con-ventions in Common Usage by Automotive Companies

Figure F.1—Male Cap Electrode Ordering Codes

Figure F.1M—Male Cap Electrode Ordering Codes

Figure F.2—Male Cap Electrode Dimensions

Figure F.2M—Male Cap Electrode Dimensions

Figure F.3—Male Cap Electrode Nose Descriptions

Figure F.3M—Male Cap Electrode Nose Descriptions

Figure F.4—Male Cap Electrode Adaptor Shank—Ordering Codes

Figure F.4M—Male Cap Electrode Adaptor Shank—Ordering Codes

Figure F.5—Male Cap Electrode Adaptor Shank—Dimensional Specifications

Figure F.5M—Male Cap Electrode Adaptor Shank—Dimensional Specifications

Figure F.6—3/4 in Increased Water Flow Male CapElectrodes—Ordering Codes

Figure F.6M—19 mm Increased Water Flow MaleCap Electrodes—Ordering Codes

Figure F.7—3/4 in Increased Water Flow Male CapElectrodes—Nose Design

Figure F.7M—19 mm Increased Water Flow MaleCap Electrodes—Nose Design

Figure F.8—3/4 in Increased Water Flow Male CapElectrodes—Dimensions

Figure F.8M—19 mm Increased Water Flow MaleCap Electrodes—Dimensions

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

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

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

Figure F.11—Straight Adaptor for Type “F” FemaleCap Electrodes—Ordering Codes

Figure F.12—Straight Adaptor for Type “F” FemaleCap Electrodes—Description

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

Annex G—Female Cap Electrode and Adaptor Conven-tions in Common Usage by Automotive Companies

Figure G.1—Nomenclature for Straight Adaptors andAssemblies for Female Cap Electrodes with RWMA#5 Taper

Figure G.1M—Nomenclature for Straight Adaptorsand Assemblies for Female Cap Electrodes withRWMA #5 Taper

Figure G.2—Nomenclature for Straight Adaptors andAssemblies for Female Cap Electrodes with RWMA#4 Cap and RWMA #4 Tapers

Figure G.2M—Nomenclature for Straight Adaptorsand Assemblies for Female Cap Electrodes withRWMA #4 Cap and RWMA #4 Tapers

Figure G.3—Nomenclature for Straight Adaptorsand Caps for Female Cap Electrodes with RWMA#6 Taper

Figure G.3M—Nomenclature for Straight Adaptorsand Caps for Female Cap Electrodes with RWMA#6 Taper

Figure G.4—Nomenclature for Female ElectrodeCaps

Figure G.4M—Nomenclature for Female ElectrodeCaps

Annex H—Guidelines for the Preparation of TechnicalInquiries

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Table 3Coding for Standard Straight Electrodes

A – 2 4 1 2

Length in 1/4 in (6.4 mm) increments, i.e., 12 = 3 in (76.2 mm)

4 = #4 RW Size Electrode, 31/64 in (12.2 mm) or 1/2 in (12.7 mm) Dia.5 = #5 RW Size Electrode, 5/8 in (15.9 mm) Dia. (see Clause 7)6 = #6 RW Size Electrode, 3/4 in (19.1 mm) Dia.7 = #7 RW Size Electrode, 7/8 in (22.2 mm) Dia.

1 = RWMA Group A, Class 1 Material2 = RWMA Group A, Class 2 Material (see 4.3 and 4.4)3 = RWMA Group A, Class 3 Material20 = RWMA Group C, Class 20 Material

A = Electrode with “A” (Pointed) NoseB = Electrode with “B” (Dome) NoseC = Electrode with “C” (Flat) Nose (Figure 1)D = Electrode with “D” (Offset) NoseE = Electrode with “E” (Truncated) NoseF = Electrode with “F” (Radius) Nose

Source: Adapted from RWMA Bulletin 16, Resistance Welding Equipment Standards, 1.8.16, p. 1-8-23, January 1996.

Figure 1—Electrode Types

“A” POINTED “B” DOME

“C” FLAT “D” OFFSET

“E” TRUNCATED “F” RADIUS

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Table 4Coding for Single-Bend Electrodes

S A – 3 S 6 1 6 1 2 1 5

15 = Angle of Bend in Degrees

12 = Amount of Offset in 1/16 in (1.59 mm) increments= [i.e., 12 = 12/16 in (19.1 mm) = 3/4 in (19.1 mm) Offset]

Electrode Length in 1/4 in (6.4 mm) increments [i.e., 12 = 3 in (76.2 mm)]

T 4 = #4 RW Taper on 31/64 in (12.2 mm) or 1/2 in (12.7 mm) Dia. StockT 5 = #5 RW Taper on 5/8 in (15.9 mm) Dia. StockT 6 = #6 RW Taper on 3/4 in (19.1 mm) Dia. StockT 7 = #7 RW Taper on 7/8 in (22.2 mm) Dia. Stock (see Clause 9)

S 4 = No Taper on 1/2 in (12.7 mm) Dia. StockS 5 = No Taper on 5/8 in (15.9 mm) Dia. StockS 6 = No Taper on 3/4 in (19.1 mm) Dia. StockS 5 = No Taper on 7/8 in (22.2 mm) Dia. Stock

2 = RWMA Group A, Class 2 Material (see 4.3 and 4.4)3 = RWMA Group A, Class 3 Material

S A = Single-Bend “A” (Pointed) Nose ElectrodeS B = Single-Bend “B” (Dome) Nose ElectrodeS C = Single-Bend “C” (Flat) Nose Electrode (Figure 1)S D = Single-Bend “D” (Offset) Nose ElectrodeS E = Single-Bend “E” (Truncated) Nose ElectrodeS F = Single-Bend “F” (Radius) Nose Electrode


Figure 2—Single-Bend Electrode Terminology

REFER TO “STANDARD STRAIGHTELECTRODES WITH TAPEREDSHANKS” FOR DIMENSION ANDTOLERANCE INFORMATION

ANGLE OFBEND INDEGREES

TAPERED ORSTRAIGHT

OFFSET IN1/16 in (1.6 mm)INCREMENTS±1/16 in (1.6 mm)

LENGTH IN 1/4 in (6.4 mm) INCREMENTS±1/16 in (1.6 mm)

––

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Table 5Coding for Double-Bend Electrodes

D A – 2 T 5 1 6 – 1 212 = Amount of Offset in 1/16 in (1.59 mm) increments

= [i.e., 12 = 12/16 in (19.1 mm) = 3/4 in (19.1 mm) Offset]

Electrode Length in 1/4 in (6.4 mm) increments [i.e., 16 = 4 in (101.6 mm)]




D A = Double-Bend “A” (Pointed) Nose ElectrodeD B = Double-Bend “B” (Dome) Nose ElectrodeD C = Double-Bend “C” (Flat) Nose Electrode (Figure 1)D D = Double-Bend “D” (Offset) Nose ElectrodeD E = Double-Bend “E” (Truncated) Nose ElectrodeD F = Double-Bend “F” (Radius) Nose Electrode


Figure 3—Double-Bend Electrode Terminology

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Table 6Coding for Standard Male Cap Electrodes

M A – 2 54 = #4 RW Size on 31/64 in (12.2 mm) or 1/2 in (12.7 mm) Dia. Stock5 = #5 RW Taper on 5/8 in (15.9 mm) Dia. Stock6 = #6 RW Taper on 3/4 in (19.1 mm) Dia. Stock7 = #7 RW Taper on 7/8 in (22.2 mm) Dia. Stock (see Clause 8)


M A = Male Cap Electrode with “A” (Pointed) NoseM B = Male Cap Electrode with “B” (Dome) Nose ElectrodeM C = Male Cap Electrode with “C” (Flat) Nose Electrode (Figure 4)M D = Male Cap Electrode with “D” (Offset) Nose ElectrodeM E = Male Cap Electrode with “E” (Truncated) Nose ElectrodeM F = Male Cap Electrode with “F” (Radius) Nose Electrode


Figure 4—Male Cap Electrode Types

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Table 7Coding for Standard Female Cap Electrodes

F A – 2 54 = #4 RW Size on 31/64 in (12.2 mm) or 1/2 in (12.7 mm) Dia. Stock5 = #5 RW Taper on 5/8 in (15.9 mm) Dia. Stock6 = #6 RW Taper on 3/4 in (19.1 mm) Dia. Stock7 = #7 RW Taper on 7/8 in (22.2 mm) Dia. Stock (see Clause 8)


F A = Female Cap Electrode with “A” (Pointed) NoseF B = Female Cap Electrode with “B” (Dome) Nose ElectrodeF C = Female Cap Electrode with “C” (Flat) Nose Electrode (Figure 5)F D = Female Cap Electrode with “D” (Offset) Nose ElectrodeF E = Female Cap Electrode with “E” (Truncated) Nose ElectrodeF F = Female Cap Electrode with “F” (Radius) Nose Electrode


Figure 5—Female Cap Electrode Types

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Table 8Coding for Straight Cap-Adaptor Shanks for Male Electrode Caps

S M – 2 T 5 1 2Electrode Length in 1/4 in (6.4 mm) increments [i.e., 12 = 3 in (76.2 mm)] (Figure 6-L2)




S M = Straight adaptor shank for Male cap electrodes (Figure 6)


Figure 6—Straight Cap-Adaptor Shank for Male Cap

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Table 9Coding for Single-Bend Adaptor Shanks for Male Electrode Caps

S M S – 3 S 6 1 6 – 1 2 – 1 515 = Angle of Bend in Degrees

12 = Amount of Offset in 1/16 in (1.59 mm) increments= [i.e., 12 = 12/16 in (19.1 mm) = 3/4 in (19.1 mm) Offset]

Shank Length in 1/4 in (6.4 mm) increments [i.e., 16 = 4 in (101.6 mm)] (Figure 7)




S M S = Adaptor shank for Male cap electrodes with Single-Bend (Figure 7)


Figure 7—Single-Bend Cap-Adaptor Shank for Male Cap

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Table 10Coding for Double-Bend Adaptor Shanks for Male Electrode Caps

S M D – 2 T 5 1 6 – 1 212 = Amount of Offset in 1/16 in (1.59 mm) increments

= [i.e., 12 = 12/16 in (19.1 mm) = 3/4 in (19.1 mm) Offset]

Electrode Length in 1/4 in (6.4 mm) increments [i.e., 16 = 4 in (101.6 mm)] (Figure 8)




S M D = Adaptor shank for Male cap electrodes with Double-Bend (Figure 8)


Figure 8—Double-Bend Cap-Adaptor Shank for Male Cap

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Table 11Coding for Straight Cap-Adaptor Shanks for Female Electrode Caps

S F – 2 T 5 1 2Electrode Length in 1/4 in (6.4 mm) increments [i.e., 12 = 3 in (76.2 mm)] (Figure 9-L2)




S F = Straight adaptor shank for Female cap electrode (Figure 9)


Figure 9—Straight Cap-Adaptor Shank for Female Cap

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Table 12Coding for Single-Bend Adaptor Shanks for Female Electrode Caps

S F S – 3 S 6 1 6 – 1 2 – 1 515 = Angle of Bend in Degrees

12 = Amount of Offset in 1/16 in (1.59 mm) increments= = [i.e., 12 = 12/16 in (19.1 mm) = 3/4 in (19.1 mm) Offset]

Shank Length in 1/4 in (6.4 mm) increments [i.e., 16 = 4 in (101.6 mm)] (Figure 10)




S F S = Adaptor shank for Female cap electrodes with Single-Bend (Figure 10)


Figure 10—Single-Bend Cap-Adaptor Shank for Female Cap

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Table 13Coding for Double-Bend Adaptor Shanks for Female Electrode Caps

S F D – 2 T 5 1 6 – 1 212 = Amount of Offset in 1/16 in (1.59 mm) increments

= [i.e., 12 = 12/16 in (19.1 mm) = 3/4 in (19.1 mm) Offset] (Figure 11)

Electrode Length in 1/4 in (6.4 mm) increments [i.e., 16 = 4 in (101.6 mm)] (Figure 11)




S F D = Adaptor shank for Female cap electrodes with Double-Bend (Figure 11)


Figure 11—Double-Bend Cap-Adaptor Shank for Female Cap

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Table 14Standard Dimensions for Straight Electrodes, Tapers, and Water Holes

Electrode Number(RWMA Class 2)Material Assumed

LOverallLengthin (mm)

Tol. ±0.010 in (±0.25 mm)

EExtensionfrom Std. Holder(Ref.)

in (mm)

MMajorDia.

in (mm)

TRWMA TaperSize

WWater Hole

Dia. in (mm) Tol. ±0.010 in (±0.25 mm)

JMinor

Taper Dia. (Ref.)

in (mm)

Ka

Taper Dia.@ 1/2 in

(12.7 mm)Tol. ±0.010 in

(0.25 mm)

A, B, C, D, E, or F 024050240602407024080240902420024110241202413024140241502416

1.25 (31.8)01.50 (38.1)01.75 (44.5)02.00 (50.8)02.25 (57.2)02.50 (63.5)02.75 (69.9)03.00 (76.2)03.25 (82.6)03.50 (88.9)03.75 (95.3)04.00 (101.6)

0.75 (19.1)01.00 (25.4)01.25 (31.8)01.50 (38.1)01.75 (44.5)02.00 (50.8)02.25 (57.2)02.50 (63.5)02.75 (69.9)03.00 (76.2)03.25 (82.6)03.50 (88.9)0

0.482or

0.500(12.7)

4 0.28(7.1)

0.438(11.1)

0.463(11.8)

A, B, C, D, E, or F 025050250602507025080250902510025110251202513025140251502516

1.25 (31.8)01.50 (38.1)01.75 (44.5)02.00 (50.8)02.25 (57.2)02.50 (63.5)02.75 (69.9)03.00 (76.2)03.25 (82.6)03.50 (88.9)03.75 (95.3)04.00 (101.6)

0.50 (12.7)00.75 (19.1)01.00 (25.4)01.25 (31.8)01.50 (38.1)01.75 (44.5)02.00 (50.8)02.25 (57.2)02.50 (63.5)02.75 (69.9)03.00 (76.2)03.25 (82.6)0

0.625(15.8) 5 0.38

(9.5)0.588(14.9)

0.613(15.6)

A, B, C, D, E, or F 026060260802610026120261402616

1.50 (38.1)02.00 (50.8)02.50 (63.5)03.00 (76.2)03.50 (88.9)04.00 (101.6)

0.625 (15.9)1.125 (28.6)1.625 (41.3)2.125 (54)0.2.625 (66.7)3.125 (79.4)

0.750(19.1) 6 0.44

(11.1)0.706(17.9)

0.731(18.6)

A, B, C, D, E, or F 027060270802710027120271402716

1.50 (38.1)02.00 (50.8)02.50 (63.5)03.00 (76.2)03.50 (88.9)04.00 (101.6)

0.375 (9.5)00.875 (22.2)1.375 (34.9)1.875 (48.1)2.375 (60.3)2.875 (73)0.

0.875(22.2) 7 0.50

(12.7)0.819(20.8)

0.844(21.4)

a Further details for measurements of standard electrode tapers can be found in the Supplemental Materials in Annex B.

Source: Adapted from RWMA Bulletin 16, Resistance Welding Equipment Standards, Tables 1.8.18 and 1.8.19, pp. 1-8-24 to 1.8.27, January 1996.

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Figure 12—Standard for Straight Electrodes

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Source: Adapted from RWMA Bulletin 16, Resistance Welding Equipment Standards, Tables 1.8.18 and 1.8.19, pp. 1-8-25 to 1-8-26, January 1996.


Figure 13—Nose Configurations for Standard Straight Electrodes

Table 15Standard Dimensions for Standard Straight Electrode Noses

Nose StyleRWMA

Taper Size

MMajor Dia.

in (mm)

GDistanceto Facein (mm)

Tol. ±0.013 in(0.8 mm)

DDiameter

of Flatin (mm)

Tol. ±0.015 in(0.4 mm)

NNose Length

in (mm)Tol. ±0.03 in

(0.8 mm)

RRadiusin (mm)

Tol. ±0.010 in(0.25 mm)

SAngle

Tol. ±0°30'

A—PointedB—DomeC—FlatD—OffsetE— TruncatedF— Radius

4 0.482 or0.50 (12.7) 0.50 (12.7)

0.19 (4.8)0.19 (4.8)Stock Size0.19 (4.8)0.19 (4.8)

—

0.75 (19.1)0.25 (6.4)0

————

0.16 (4.1)0.16 (4.1)

———

2 (50.8)

6°——50°45°—


5 0.625 (15.8) 0.75 (19.1)

0.25 (6.4)0.25 (6.4)Stock Size0.25 (6.4)0.25 (6.4)

—

0.88 (22.2)0.38 (9.5)0

————

0.22 (5.6)0.22 (5.6)

———

2 (50.8)

6°——45°45°—


6 0.75 (19.1) 0.75 (19.1)

0.28 (7.1)0.28 (7.1)Stock Size0.28 (7.1)0.28 (7.1)

—

1 (25.4)0.38 (9.5)

————

0.28 (7.1)0.28 (7.1)

———

4 (101.6)

6°——45°45°—


7 0.875 (22.2) 0.75 (19.1)

0.31 (7.9)0.31 (7.9)Stock Size0.31 (7.9)0.31 (7.9)

—

1.12 (28.6)0.38 (9.5)0

————

0.34 (8.6)0.34 (8.6)

———

4 (101.6)

6°——45°45°—

AW

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Source: Adapted from RWMA Bulletin 16, Resistance Welding Equipment Standards, Tables 1.8.20 and 1.8.21, pp. 1-8-31 to 1-8-33, January 1996.

Table 16Standard Dimensions for Male Cap Electrodes

Nose Style

RWMA TaperSize

MMajorDia.

in (mm)


Tol.±0.03 in(0.8 mm)

DDiameter

of Flatin (mm)

Tol.±0.015 in(0.4 mm)

NNose

LengthTol.

in (mm)±0.03 in(0.8 mm)

RRadiusin (mm)

Tol.±0.010 in(0.25 mm)

SAngle

in (mm)Tol.

±0°30'

LOverallLengthin (mm)

Tol.±0.010 in(0.25 mm)

TTaperLengthin (mm)

WWater

Hole Dia.in (mm)

Tol.±0.010 in(0.25 mm)

HMinor

Taper Dia.in (mm)(Ref.)

Dia. K@ Dim. P

in (mm) Tol.+0.000/–0.000 in

(+0.025/–0.000 mm)


40.482

or 0.50(12.7)

3/8(9.5)

0.19 (4.8)0.19 (4.8)Stock Size0.19 (4.8)0.19 (4.8)

—

0.38 (9.5)00.25 (6.4)0

————

0.16 (4.1)0.16 (4.1)

———

2.00 (50.1)

18°15'——50°45°—

1.125(28.6)

0.38(9.5)

0.28(7.1)

0.361(9.2)

0.375 @ 0.275(9.5 @ 7.0)


5 0.625(15.8)

3/8(9.5)

0.25 (6.4)0.25 (6.4)Stock Size0.25 (6.4)0.25 (6.4)

—

0.50 (12.7)0.38 (9.5)0

————

0.22 (5.6)0.22 (5.6)

———

2.00 (50.1)

15°30'——45°45°—

1.250(31.8)

0.50(12.7)

0.31(7.9)

0.396(10.1)

0.415 @ 0.390(10.5 @ 9.6)


6 0.750(1.19)

3/8(9.5)

0.28 (7.1)0.28 (7.1)Stock Size0.28 (7.1)0.28 (7.1)

—

0.75 (19.1)0.38 (9.5)0

————

0.28 (7.1)0.28 (7.1)

———

4.00 (101.6)

13°30'——45°45°—

1.625(41.3)

0.63(16)

0.38(12.1)

0.476(12.1)

0.501 @ 0.500(12.7 @ 12.7)


7 0.875(22.2)

3/8(9.5)

0.31 (7.9)0.31 (7.9)Stock Size0.31 (7.9)0.31 (7.9)

—

0.75 (19.1)0.38 (9.5)0

————

0.34 (8.6)0.34 (8.6)

———

4.00 (101.6)

15°——45°45°—

1.625(41.3)

0.63(16)

0.50(12.7)

0.588(14.9)

0.613 @ 0.500(15.6 @ 12.7)

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Figure 14—Standard Male Cap Electrodes

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Source: Adapted from RWMA Bulletin 16, Resistance Welding Equipment Standards, Table 1.8.22, p. 1-8-35, January 1996.

Table 17Standard Dimensions for Straight Cap-Adaptor Shanks for Male Cap Electrodes

Cap AdaptorShank Number

L1OAL Assy.

Lengthin (mm)

L2ShankLengthin (mm)

Tol.±0.010 in(0.25 mm)

EExtensionfrom Std.Holder

(Approx.)

MMajorDia.

in (mm)

TRWMATaperSize

KCap TaperGauge Dia.

in (mm)Tol.

+0.000/–0.001 in(0.025 mm)

JMinimum

TaperEngagement

in (mm)

WWater Hole

Dia.in (mm)

Tol. ±0.010 in (0.25 mm)

HMinor

Taper Dia.in (mm)(Ref.)

ITaper Dia.

@ Pin (mm)

Tol. ±0.001 in(0.025 mm)

SM- 2T 4052T 4062T 4072T 4082T 4092T 4102T 4112T 4122T 4132T 4142T 4152T 416

2.00 (50.8)02.25 (57.2)02.50 (63.5)02.75 (69.9)03.00 (76.2)03.25 (82.6)03.50 (88.9)03.75 (95.3)04.00 (101.6)4.25 (107.9)4.50 (114.3)4.75 (120.7)

1.25 (31.8)01.50 (38.1)01.75 (44.5)02.00 (50.8)02.25 (57.2)02.50 (63.5)02.75 (69.9)03.00 (76.2)03.25 (82.6)03.50 (88.9)03.75 (95.3)04.00 (101.6)

1.50 (38.1)001.75 (44.5)002.00 (50.8)002.25 (57.2)002.50 (63.5)002.75 (69.9)003.00 (76.2)003.25 (82.6)003.50 (88.9)003.75 (95.3)004.00 (101.6)04.25 (107.9)0

0.482or 0.500(12.7)

4 0.375(9.53)

0.41(10.3)

0.28(7.1)

0.438(11.12)

0.463 @ 0.50(11.76 @ 1.27)

SM- 2T 5052T 5062T 5072T 5082T 5092T 5102T 5112T 5122T 5132T 5142T 5152T 516

2.00 (50.8)02.25 (57.2)02.50 (63.5)02.75 (69.9)03.00 (76.2)03.25 (82.6)03.50 (88.9)03.75 (95.3)04.00 (101.6)4.25 (107.9)4.50 (114.3)4.75 (120.7)

1.25 (31.8)01.50 (38.1)01.75 (44.5)02.00 (50.8)02.25 (57.2)02.50 (63.5)02.75 (69.9)03.00 (76.2)03.25 (82.6)03.50 (88.9)03.75 (95.3)04.00 (101.6)

1.25 (31.8)001.50 (38.1)001.75 (44.5)002.00 (50.8)002.25 (57.2)002.50 (63.5)002.75 (69.9)003.00 (76.2)003.25 (82.6)003.50 (88.9)003.75 (95.3)004.00 (101.6)0

0.625(15.8) 5 0.415

(10.54)0.53

(13.5)0.38(9.5)

0.588(14.94)

0.613 @ 0.50(15.57 @ 1.27)

SM- 2T 6082T 6102T 6122T 6142T 616

3.00 (76.2)03.50 (88.9)04.00 (101.6)4.50 (114.3)5.00 (127)0.

2.00 (50.8)02.50 (63.5)03.00 (76.2)03.50 (88.9)04.00 (101.6)

2.125 (54)0.02.625 (66.7)03.125 (79.4)03.625 (92.1)04.125 (104.8)

0.750(19) 6 0.501

(12.73)0.66

(16.7)0.44

(11.1)0.706

(17.93)0.713 @ 0.50

(18.57 @ 1.27)

SM- 2T 7082T 7122T 716

3.00 (76.2)04.00 (101.6)5.00 (127)0.

1.00 (25.4)03.00 (76.2)04.00 (101.6)

1.875 (48.1)02.875 (73)0.03.875 (98.4)0

0.875(22) 7 0.613

(15.57)0.66

(16.7)0.50

(12.7)0.819

(20.80)0.844 @ 0.50

(21.44 @ 12.7)

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Figure 15—Cap-Adaptor Shanks for Male Cap Electrodes

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Table 18Standard Dimensions for Female Cap Electrodes

Nose Style

RWMATaper SizeT = 1/9.8

MMajorDia.

in (mm)


Tol.±0.03 in

(0.76 mm)

DDiameter

of Flatin (mm)

Tol. ±0.015 in(0.38 mm)

NNose

Lengthin (mm)

Tol. ±0.03 in(0.76 mm)

RRadius Tol.±0.010 in(0.25 mm)

SAngle Tol. ±0.010 in(0.25 mm)

LOverall

Length Tol. ±0.010 in(0.25 mm)

JMajor

Taper Dia. Tol.+0.001/–0.000 in(0.025/0.000 mm)

PTaper

Dept. Tol.+0.020/–0.000 in (0.51/0.00 mm)


40.482

or 0.500(12.7)

0.46(11.7)

0.19 (4.8)0.19 (4.8)Stock Size0.19 (4.8)0.19 (4.8)

—

0.38 (9.5)00.25 (6.4)0

————

0.16 (4.1)00.16 (4.1)0

———

2.00 (50.1)

15°20'——50°45°—

0.840(21.3)

0.3940(10.01)

0.360(9.1)0


5 0.625(15.8)

0.37(9.4)

0.25 (6.4)0.25 (6.4)Stock Size0.25 (6.4)0.25 (6.4)

—

0.50 (12.7)0.38 (9.5)0

————

0.22 (5.6)00.22 (5.6)0

———

2.00 (50.1)

17°——45°45°—

0.880(20.3)

0.4946(12.56)

0.392(9.9)0


6 0.750(19.1)

0.37(9.4)

0.28 (7.1)0.28 (7.1)Stock Size0.28 (7.1)0.28 (7.1)

—

0.75 (19.1)0.38 (9.5)0

————

0.28 (7.1)00.28 (7.1)0

———

4.00 (101.6)

20°——45°45°—

1.000(25.4)

0.625(15.88)

0.434(11.0)

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Figure 16—Standard Female Cap Electrodes

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Table 19Standard Dimensions for Straight Cap-Adaptor Shanks for Female Cap Electrodes

Cap AdaptorShank Number

L1OAL Assy.

Lengthin (mm)

L2ShankLengthin (mm)

Tol.±0.010 in(0.25 mm)

EExtensionFrom Std.

Holder(Approx.)in (mm)

MMajorDia.

in (mm)

TRWMATaperSize

KCap TaperGauge Dia.

in (mm)Tol. + 0.000/–0.0001 in

(+0/–0.025 mm)

XTaper

Engagementin (mm)

WWater Hole

Dia.in (mm)

Tol. ±0.010 in(0.25 mm)

HMinor

Taper Dia.(Ref.)

in (mm)

ITaper Dia.

@ Pin (mm)

Tol. ±0.001 in(0.025 mm)

YTaper

Lengthin (mm)

Tol. ±0.002 in(0.05 mm)

SF- 2T 4052T 4062T 4072T 4082T 4092T 4102T 4112T 4122T 4132T 4142T 4152T 416

1.85 (47).02.10 (53.3)2.35 (59.7)2.60 (66.0)2.85 (72.4)3.10 (78.7)3.35 (85.1)3.60 (91.4)3.85 (97.8)4.10 (104.1)4.35 (110.5)4.60 (116.8)

1.25 (31.8)1.50 (38.1)1.75 (44.5)2.00 (50.8)2.25 (57.2)2.50 (63.5)2.75 (69.9)3.00 (76.2)3.25 (82.6)3.50 (88.9)3.75 (95.3)4.00 (101.6)

1.35 (34.3)1.60 (40.6)1.85 (46.9)2.10 (53.3)2.35 (59.7)2.60 (66.0)2.85 (72.4)3.10 (78.7)3.35 (85.1)3.60 (91.4)3.85 (97.8)4.10 (104.1)

0.482or

0.500(12.7)

4 0.402(10.21)

0.380(9.65)

0.28(7.1)

0.438(11.13)

0.463 @ 0.50(11.76 @ 1.27)

0.450(11.43)

SF- 2T 5052T 5062T 5072T 5082T 5092T 5102T 5112T 5122T 5132T 5142T 5152T 516

1.89 (48.0)2.14 (54.4)2.39 (60.7)2.64 (67.1)2.89 (73.4)3.14 (79.8)3.39 (86.1)3.64 (92.5)3.89 (98.8)4.14 (105.2)4.39 (111.5)4.64 (117.9)

1.25 (31.8)1.50 (38.1)1.75 (44.5)2.00 (50.8)2.25 (57.2)2.50 (63.5)2.75 (69.9)3.00 (76.2)3.25 (82.6)3.50 (88.9)3.75 (95.3)4.00 (101.6)

1.14 (28.9)1.39 (35.3)1.64 (41.7)1.89 (48.0)2.14 (54.4)2.39 (60.7)2.64 (67.1)2.89 (73.4)3.14 (79.8)3.39 (86.1)3.64 (92.5)3.89 (98.8)

0.625(15.8) 5 0.502

(12.75)0.359(9.12)

0.38(9.5)

0.588(14.94)

0.613 @ 0.50(15.57 @ 1.27)

0.442(11.23)

SF- 2T 6082T 6102T 6122T 6142T 616

3.00 (76.2)3.50 (88.9)4.00 (101.6)4.50 (114.3)5.00 (127)

2.00 (50.8)2.50 (63.5)3.00 (76.2)3.50 (88.9)4.00 (101.6)

2.125 (53.9)2.625 (66.7)3.125 (79.4)3.625 (92.1)4.125 (104.8)

0.750(19.1) 6 0.633

(16.08)0.401

(10.19)0.44

(11.1)0.706

(17.93)0.731 @ 0.50

(18.57 @ 1.27)0.491

(12.47)

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Figure 17—Cap-Adaptor Shanks for Female Cap Electrodes

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

(not part of RWMA standards)

Major Dia. in (mm) [RWMA Taper #] Tube Outside Dia. in (mm) Tube Wall Thickness in (mm)

0.482 or 0.500 (13) [#4]0.625 (16) [#5]0.750 (19) [#6]0.875 (22) [#7]

0.182 (4.6)0.250 (6.4)0.250 (6.4)0.250 (6.4)

0.017 (0.43)0.032 (0.81)0.032 (0.81)0.032 (0.81)

Table 21Double-Bend Electrodes Listed by the RWMA

Major Dia. in (mm)[RWMA Taper #1] Code

OAL (Length) in (mm)(see 6.2.1.3)

Offset in (mm)(see 6.2.1.3)

Nose(see 7.2)

0.482 or 0.500 (12.7) [#4]

DA 2T 408 08DA 2T 409 08DA 2T 410 08

2.00 (50.8)2.25 (57.2)2.50 (63.5)

0.500 (12.7) A

DA 2T 408 12DA 2T 409 12DA 2T 410 12

2.00 (50.8)2.25 (57.2)2.50 (63.5)

0.750 (19.1) A

DA 2T 409 16DA 2T 410 16DA 2T 411 16DA 2T 412 16DA 2T 413 16DA 2T 414 16

2.25 (57.2)2.50 (63.5)2.75 (69.9)3.00 (76.2)3.25 (82.6)3.50 (88.9)

1.000 (25.4) A

DA 2T 410 20DA 2T 411 20DA 2T 412 20

2.50 (63.5)2.75 (69.9)3.00 (76.2)

1.250 (31.8) A

0.625 (16) [#5]

DA 2T 510 08DA 2T 511 08DA 2T 512 08DA 2T 513 08

2.50 (63.5)2.75 (69.9)3.00 (76.2)3.25 (82.6)

0.500 (12.7) A

DA 2T 511 12DA 2T 512 12DA 2T 513 12

2.75 (69.9)3.00 (76.2)3.25 (82.6)

0.750 (19.1) A

DA 2T 511 16DA 2T 512 16DA 2T 513 16DA 2T 514 16

2.75 (69.9)3.00 (76.2)3.25 (82.6)3.50 (88.9)

1.000 (25.4) A

DA 2T 511 20DA 2T 512 20DA 2T 513 20DA 2T 514 20

2.75 (69.9)3.00 (76.2)3.25 (82.6)3.50 (88.9)

1.250 (31.8) A

DA 2T 511 24 2.75 (69.9) 1.500 (38.1) A

DA 2T 511 28 2.75 (69.9) 1.750 (44.5) A


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AWS D8.6:2005

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Annex A (Informative)

Recommended Electrode Materials for Spot Welding Dissimilar and Similar Metals

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

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32

Source: Adapted from RWMA Bulletin 16, Resistance Welding Equipment Standards, Table 1.8.11.5, p. 1-8-14, January 1996.

DISSIMILAR FERROUS METALS

SIDE 2 METAL

SIDE 1 METAL

NICKEL &NICKEL ALLOYS

COLD-ROLLED STEEL TIN PLATE

TERNEPLATE

GALVANIZED STEEL

CADMIUM PLATE

CHROME PLATE

STAINLESS STEEL

B 2 A 2 B 1, 2, 20 B 1, 2, 20 B 1, 2, 20 B 1, 2, 20 B 2

2, 3 2, 3 2, 3 2, 3 2, 3 2, 3 2, 3

CHROME PLATE

B 2 B 2 B 1, 2, 20 B 1, 2, 20 B 1, 2, 20 B 1, 2, 20

2 2 2 2 1, 2, 20 2

CADMIUM PLATE

B 2 B 2 C 1, 20 20 B 1, 2, 20 B 1, 2, 20

1, 2, 20 2 1, 2, 20 1, 2, 20 1, 2, 20

GALVANIZED STEEL

C 2 B 2 B 1, 2, 20 C 1, 2, 20

1, 2, 20 1, 2, 20 1, 2, 20 1, 2, 20

TERNEPLATE

C 2 B 2 C 1, 2, 20

1, 2, 20 1, 2, 20 1, 2, 20

TINPLATE

C 2 B 2

1, 2, 20 1, 2, 20

COLD-ROLLED STEEL

C 2

2

BLOCK INTERPRETATION

WELDABILITY

A = EXCELLENTB = GOOODC = FAIR

RWMAELECTRODE

CLASS(See Table 1)

for SIDE 1

RWMAELECTRODE

CLASS(See Table 1)

for SIDE 2

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Source: Adapted from RWMA Bulletin 16, Resistance Welding Equipment Standards, Tables 1.8.11.1 to 1.8.11.4, p. 1-8-13, January 1996.

SIMILAR FERROUS METALS

STAINLESS STEEL

GALVANIZED STEEL TIN PLATE

TERNEPLATE

CADMIUMPLATE

CHROMEPLATE

COLD-ROLLED STEEL

Side 1 A 2,3a A 1, 2, 20 B 1, 2, 20 B 1, 2, 20 A 1, 2, 20 A 2 A 2

Side 2 2, 3 2, 3 2, 3 2, 3 2, 3 2, 3 2, 3

SIMILAR NONFERROUS METALS

ALUMINUM/ALUMINUM

ALLOYS COPPERNICKEL-SILVER

NICKEL & NICKEL ALLOYS

PHOSPHOR BRONZE

YELLOW BRASS

REDBRASS

Side 1 A 1 C 13, 14 A 2 A 2 A 2 A 2 A 2

Side 2 1 13, 14 2 2 2 2 2

SIMILAR NONFERROUS METALS

MAGNESIUM TITANIUM SILICON BRONZECUPRO-NICKEL NICKEL

Side 1 B 1 A 2, 3 A 2 B 2 A 2 B 2

Side 2 1 2, 3 2 2 2 2

REFRACTORY METALS

TUNGSTEN MOLYBDENUM

CHROMEPLATE

STAINLESSSTEEL

NICKEL & NICKEL ALLOYS

Side 1 B 2 B 2, 3 B 2, 3a B 2

Side 2 2 2 2, 3a 2

a Indicates a second choice of alloy class which can be used, however the sameelectrode alloy should be used on both sides for all materials.

BLOCK INTERPRETATION

WELDABILITY

A = EXCELLENTB = GOOODC = FAIR

RWMAELECTRODE

CLASS(See Table 1)

for SIDE 1

RWMAELECTRODE

CLASS(See Table 1)

for SIDE 2


AWS D8.6:2005

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AWS D8.6:2005

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Annex B (Informative)

Standard Gauges for Confirmation ofRWMA “Standard Electrode Tapers”


AWS D8.6:2005

36

(See 6.2.1 straight, 6.2.2 single-bend, 6.2.3 double-bend, and 6.4 holder end of cap-adaptor shanks.)

Source: Adapted from RWMA Bulletin 16, Resistance Welding Equipment Standards, Figure 1.8.6, p. 1-8-48, January 1996.

RWMATaper

A Dim.in (mm)

B1 Dim.in (mm)

B2 Dim.in (mm)

C Dim.in (mm)

#4 0.463 (11.7) 0.500 (12.7) 0.560 (14.2) 0.10 (2.5)

#5 0.625 (15.9) 0.750 (19.1) 0.810 (20.6) 0.25 (6.4)

#6 0.750 (19.1) 0.875 (22.2) 0.935 (23.7) 0.25 (6.4)

#7 0.875 (22.2) 1.125 (28.6) 1.185 (30.1) 0.25 (6.4)

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Annex C (Informative)

Standard Gauges for Confirmation of RWMA“Standard Male Cap Electrode Tapers”


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(See 8.1 male cap electrodes and 8.2 cap end of cap-adaptor shanks for male cap electrodes.)


RWMACap Taper

A Dim.in (mm)

B1 Dim.in (mm)

C Dim.in (mm)

#4 0.375 (9.5)0 0.285 (7.2) 0.09 (2.3)

#5 0.415 (10.5) 0.390 (9.9) 0.10 (2.5)

#6 0.501 (12.7) 0.500 (12.7) 0.10 (2.5)

#7 0.613 (15.6) 0.500 (12.7) 0.10 (2.5)

RWMACap Taper

A Dim.in (mm)

B2 Dim.in (mm)

#4 0.375 (9.5)0 0.405 (10.3)

#5 0.415 (10.5) 0.530 (13.5)

#6 0.501 (12.7) 0.655 (16.6)

#7 0.613 (15.6) 0.655 (16.6)

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(See 8.3 female cap electrodes and 8.4 cap end of cap-adaptor shanks for female cap electrodes.)


RWMACap Taper

A Dim.in (mm)

B1 Dim.in (mm)

C Dimin (mm)

#4 0.402 (10.2) 0.348 (8.8) 0.09 (2.3)

#5 0.502 (10.5) 0.380 (9.7) 0.10 (2.5)

#6 0.633 (16.1) 0.457 (11.6) 0.10 (2.5)

Annex D (Informative)

Standard Gauges for Confirmation of RWMA“Standard Female Cap Electrode Tapers”


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40


RWMACap Taper

A Dim.in (mm)

B Dim.in (mm)

#4 0.3940 (10.0) 0.347 (8.8)

#5 0.4946 (12.6) 0.379 (9.6)

#6 0.6250 (15.9) 0.421 (10.7)

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Annex E (Informative)

Recommended Sizes of Stock RWMA ElectrodeNumbers and Welding Face Diameters for

Use at Various Welding Force RangesThis annex is not a part of AWS D8.6:2005, Specification for Automotive Resistance

Spot Welding Electrodes, but is included for informational purposes only.

AWS D8.6:2005

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AWS D8.6:2005

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Annex F (Informative)

Cap Electrodes and Cap Electrode Adaptor Conventions in Common Usage by Automotive Companies


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44

Use W for welding

Use C for cap

Use 1 for spotweld cap

Nose configuration Use: A for 45° truncated cone (for steel through 0.060)(Ref. Figure F.3) AA for 30° truncated cone (use on 3/4 and 7/8 electrode)

BA for 15° face angleBB for 30° face angleBC for 45° face angle

B for angle dressing onlyC for contour dressing onlyD for narrow flange widths in steel under 0.060 thick

DD for narrow flange widths in steel over 0.060 thickR for radius faced applications

Material class Use 2 (Class 2 RWMA) for normal welding(class numbers) Use 1 (Class 1 RWMA) for special application

Use 3 (Class 3 RWMA) for special application

Cap diameter Use: 4 for 0.50 nominal diameter(in 0.12 increments) 5 for 0.62 nominal diameter

6 for 0.75 nominal diameter7 for 0.88 nominal diameter

Contact face diameter Use: A for 0.18 diameter (0.18 weld buttons)or radius (Ref. Figure F.3) B for 0.25 diameter (0.25 weld buttons)

C for 0.31 diameter (0.31 weld buttons)D for 0.35 diameter (0.35 weld buttons)1 for 0.88 radius2 for 1.12 radius3 for 2 radius

W C 1 A 2 5 B Typical cap coding (not coded for B or C caps)

Cap will have 0.25 contact face diameter

Cap will be 0.62 diameter

Cap will be made of Class 2 RWMA material

Cap will have 45° truncated cone nose All dimensions except degrees in inches

Figure F.1—Male Cap Electrodes—Ordering Codes

AWS D8.6:2005

45

Use W for welding

Use C for cap

Use 1 for spotweld cap

Nose configuration Use: A for 45° truncated cone (for steel through 1.52)(Ref. Figure F.3) AA for 30° truncated cone (use on 19 and 19.05 electrode)

BA for 15° face angleBB for 30° face angleBC for 45° face angle

B for angle dressing onlyC for contour dressing onlyD for narrow flange widths in steel under 1.52 thick




Cap diameter Use: 4 for 12.7 nominal diameter(in 0.12 increments) 5 for 15.7 nominal diameter


Contact face diameter Use: A for 4.5 diameter (4.5 weld buttons)or radius (Ref. Figure F.3) B for 6.4 diameter (6.4 weld buttons)

C for 7.9 diameter (7.9 weld buttons)D for 8.9 diameter (8.9 weld buttons)1 for 22.4 radius2 for 28.4 radius3 for 51 radius

W C 1 A 2 5 B Typical cap coding (not coded for B or C caps)




Cap will have 45° truncated cone nose All dimensions except degrees in millimeters

Figure F.1M—Male Cap Electrodes—Ordering Codes

AWS D8.6:2005

46

All dimensions except degrees in inches

Figure F.2—Male Cap Electrode Dimensions

All dimensions except degrees in millimeters

Figure F.2M—Male Cap Electrode Dimensions

AWS D8.6:2005

47

Table F.1Standard for Male Cap Electrodes

Tolerance

EFGKPSV

DiameterTaper diameterLengthHole diameterTaper locationSkirt lengthFlat maximum

1/20.3141.1000.2000.0600.4601/8

5/80.4151.1400.3200.1100.5003/16

3/40.5011.2600.3800.1200.6201/4

7/80.7011.2600.5600.0900.6209/32

±0.002+0.000/–0.001

±0.010±0.010±0.010±0.010

—

Notes: All dimensions except degrees in inches1. Ordering and material as per code shown in Figure F.1.2. All working surfaces to have a maximum finish of 30 µin (arithmetic average).3. Stamp identification mark clearly—avoid working surfaces.4. Chemically clean caps—use a procedure to minimize oxidation and to be noninsulating in nature.

Table F.1MStandard for Male Cap Electrodes

Tolerance

EFGKPSV

DiameterTaper diameterLengthHole diameterTaper locationSkirt lengthFlat maximum

13.08.0

27.95.11.5

11.73.2

16.010.528.98.12.8

12.74.8

19.012.732.09.73.0

15.76.4

22.017.832.014.22.3

15.77.1

±0.05+0.00/–0.03

±0.25±0.25±0.25±0.25

—

Notes: All dimensions except degrees in millimeters1. Ordering and material as per code shown in Figure F.1.2. All working surfaces to have a maximum finish of 0.75 µm (arithmetic average).3. Stamp identification mark clearly—avoid working surfaces.4. Chemically clean caps—use a procedure to minimize oxidation and to be noninsulating in nature.

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Figure F.3—Male Cap Electrode Nose Descriptions

For nose application,see Figure F.1.

E Diameter 1/2 5/8 3/4 7/8 1/2 5/8 3/4 7/8 1/2 5/8 3/4 7/8 1/2 5/8 3/4 7/8 1/2 5/8 3/4 7/8

θ-ContactFace Diameteror Radius ±0.005

ABCD

0.18***

*0.25

**

****

****

****

****

*0.250.310.35

**

0.310.35

Dress to suit Dress to suit

0.18***

0.180.25

**

*0.250.31

*

****

*Not recommended All dimensions except degrees in inches

E Diameter 1/2 5/8 3/4 7/8 1/2 5/8 3/4 7/8 1/2 5/8 3/4 7/8 1/2 5/8 3/4 7/8 1/2 5/8 3/4 7/8


ABCD

****

****

*0.250.310.35

**

0.310.35

1.12Ror

2.0R

1.12Ror

2.0R

0.88Ror

2.0R

0.88Ror

2.0R

0.18***

0.180.250.31

*

*0.250.310.35

**

0.310.35

0.18***

0.180.250.31

*

*0.250.310.35

**

0.310.35

0.18***

0.180.250.31

*

*0.250.310.35

**

0.310.35

*Not recommended All dimensions except degrees in inches

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Figure F.3M—Male Cap Electrode Nose Descriptions

For nose application,see Figure F.1.

E Diameter 13 16 19 22 13 16 19 22 13 16 19 22 13 16 19 22 13 16 19 22


ABCD

4.5***

4.56.47.9*

*6.4**

****

****

****

*6.47.98.8

**

7.98.9

Dress to suit Dress to suit

4.5***

4.56.4**

*6.47.9*

****

*Not recommended All dimensions except degrees in millimeters

E Diameter 13 16 19 22 13 16 19 22 13 16 19 22 13 16 19 22 13 16 19 22


ABCD

****

****

*6.47.98.9

**

7.98.9

1.12Ror

2.0R

1.12Ror

2.0R

0.88Ror

2.0R

0.88Ror

2.0R

4.5***

4.56.47.9*

*6.47.98.9

**

7.98.9

4.5***

4.56.47.9*

*6.47.98.9

**

7.98.9

4.5***

4.56.47.9*

*6.47.98.9

**

7.98.9

*Not recommended All dimensions except degrees in millimeters

AWS D8.6:2005

50

Use W for welding

Use B for adaptor

Use 1 for straight electrode

Adaptor shank Use S for straight shankUse T for tapered shank

Material Use 3 (Class 3 RWMA)

Adaptor diameter Use: 4 for 0.50 nominal diameter(in 0.12 increments) 5 for 0.62 nominal diameter


Overall length Minimum length – 8 = 2.0 for 1/2, 5/8, and 3/4 diameter(in 0.25 increments) Minimum length – 9 = 2.25 for 7/8 diameter

W B 1 T 3 6 10 Typical adaptor coding

Adaptor will be 2.5 long

Adaptor will have 0.75 diameter

Adaptor will be made of Class 3 RWMA material

Adaptor will have a tapered shank

Adaptor will be straight All dimensions in inches

Figure F.4—Male Cap Electrode Adaptor Shanks—Ordering Codes

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Use W for welding

Use B for adaptor

Use 1 for straight electrode

Adaptor shank Use S for straight shankUse T for tapered shank


Adaptor diameter Use: 4 for 12.7 nominal diameter(in 3.0 increments) 5 for 15.7 nominal diameter


Overall length Minimum length – 8 = 51 for 12.7, 16, and 19 diameter(in 6.4 increments) Minimum length – 9 = 57.2 for 21.8 diameter

W B 1 T 3 6 10 Typical adaptor coding

Adaptor will be 63 long

Adaptor will have 19.0 diameter



Adaptor will be straight All dimensions in millimeters

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

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Figure F.5—Male Cap Electrode Adaptor Shanks—Dimensional Specifications

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53

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

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54

Table F.2Standard for Male Cap Electrode and Adapter Shank

Tapered Shank Tolerance

EFG

KLNYP

DiameterTaper diameterLengthLength, minHole diameterLand diameterTaper diameterTaper locationTaper depth, min

0.4820.463

As coded2.000.28—

0.3130.500.80

5/80.625

As coded2.000.38—

0.4140.750.80

3/40.750

As coded2.000.44—

0.5000.880.94

±0.002+0.000/–0.001

±0.010—

±0.010—

+0.000/–0.001±0.010±0.010

Straight Shank Tolerance

EFG

KLNYP


1/2—

As coded2.000.280.330.313—

0.80

5/8—

As coded2.000.380.440.414—

0.80

3/4—

As coded2.000.440.560.500—

0.94

7/8—

As coded2.250.560.620.700—

0.94

±0.002—

±0.010—

±0.010±0.010

+0.000/–0.001—

±0.010

All dimensions in inches

Notes:1. Ordering and material as per code shown in Figure F.4.2. All working surfaces to have a maximum finish roughness of 30 µin (arithmetic average).3. Stamp identification mark clearly—avoid working surfaces.4. Chemically clean caps—use a procedure to minimize oxidation and to be noninsulating in nature.

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Table F.2MStandard for Male Cap Electrode and Adapter Shank

Tapered Shank Tolerance

EFG

KLNYP


12.211.8

As coded51.07.1—7.95

12.720.3

16.015.9

As coded51.09.7—

10.5219.020.3

19.019.0

As coded51.014.2—

12.7022.423.9

±0.05+0.00/–0.03

±0.25—

±0.25—

+0.03/–0.00±0.25±0.25

Straight Shank Tolerance

EFG

KLNYP


13.0—

As coded51.07.18.47.95—

20.3

16.0—

As coded51.09.7

11.210.52—

20.3

19.0—

As coded51.011.214.212.70—

23.9

11.0—

As coded57.014.215.717.78—

23.9

±0.05—

±0.25—

±0.25±0.25

+0.03/–0.00—

±0.25


Notes:1. Ordering and material as per code shown in Figure F.4.2. All working surfaces to have a maximum finish roughness of 0.75 µm (arithmetic average).3. Stamp identification mark clearly—avoid working surfaces.4. Chemically clean caps—use a procedure to minimize oxidation and to be noninsulating in nature.

AWS D8.6:2005

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AWS D8.6:2005

57

Use W for welding

Use C for cap

Use 1-1 for revised cap type electrode

Nose configuration Use: A for 45° truncated cone (for steel through 0.060)(Ref. Figure F.8) AA for 30° truncated cone (use on 3/4 electrode)

B for angle dressing onlyBA for 15° face angleBB for 30° face angleBC for 45° face angle

C for contour dressing onlyD for narrow flange widths in steel under 0.060 thick




Cap diameter Use: 6 for 0.75 nominal diameter(in 1/8 increments)

Contact face diameter Use: B for 0.25 diameter (0.25 weld buttons)(Ref. Figure F.8) C for 0.31 diameter (0.31 weld buttons)

D for 0.35 diameter (0.35 weld buttons)1 for 0.88 radius3 for 2 radius

W C 1-1 A 2 6 B Typical cap coding (not coded for B or C caps)




Cap will have 45° truncated cone nose All dimensions except degrees in inches

Figure F.6—3/4 in Increased Water FlowMale Cap Electrodes—Ordering Codes

AWS D8.6:2005

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AWS D8.6:2005

59

Use W for welding

Use C for cap

Use 1-1 for revised cap type electrode

Nose configuration Use: A for 45° truncated cone (for steel through 0.060)(Ref. Figure F.8) AA for 30° truncated cone (use on 3/4 electrode)

B for angle dressing onlyBA for 15° face angleBB for 30° face angleBC for 45° face angle

C for contour dressing onlyD for narrow flange widths in steel under 1.5 thick




Cap diameter Use: 6 for 19.0 nominal diameter(in 3.2 increments)

Contact face diameter Use: B for 6.4 diameter (6.4 weld buttons)(Ref. Figure F.8) C for 7.9 diameter (7.9 weld buttons)

D for 8.9 diameter (8.9 weld buttons)1 for 22.4 radius3 for 50.8 radius

W C 1-1 A 2 6 B Typical cap coding (not coded for B or C caps)




Cap will have 45° truncated cone nose All dimensions except degrees in millimeters

Figure F.6M—19 mm Increased Water FlowMale Cap Electrodes—Ordering Codes

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60

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

Type A AA B BA BB BC C D DD R

E Diameter 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4


BCD

0.25Note aNote a

0.250.310.35

Note bNote bNote b

0.250.310.35

0.250.310.35

0.250.310.35

Note bNote bNote b

0.250.31

Note a

0.250.310.35

0.88Ror

2.0R

a Not recommended. All dimensions in inchesb Dress to suit.

Notes:1. Ordering and material as per code shown in Figure F.6.2. All working surfaces to have a maximum finish of 30 µin (arithmetic average).3. Stamp identification mark clearly—avoid working surfaces.4. Chemically clean adaptors—use a procedure to minimize oxidation and to be noninsulating in nature.5. To be used with Figure F.5 electrode adaptors only.

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

Type A AA B BA BB BC C D DD R

E Diameter 19 19 19 19 19 19 19 19 19 19


BCD

6.4Note aNote a

6.47.98.9

Note bNote bNote b

6.47.98.9

6.47.98.9

6.47.98.9

Note bNote bNote b

6.47.9

Note a

6.47.98.9

0.88Ror

2.0R

a Not recommended. All dimensions in millimetersb Dress to suit.

Notes:1. Ordering and material as per code shown in Figure F.6.2. All working surfaces to have a maximum finish of 0.75 µm (arithmetic average).3. Stamp identification mark clearly—avoid working surfaces.4. Chemically clean adaptors—use a procedure to minimize oxidation and to be noninsulating in nature.5. To be used with Figure F.5 electrode adaptors only.

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

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

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Table F.3Standard for Increased Water Flow Male Cap Electrodes

Tolerance

EFGKPS

DiameterTaper diameterLengthHole diameterTaper locationSkirt length

3/40.5641.260.440.090.62

±0.002+0.000/–0.001

±0.010±0.010±0.010±0.010

Notes: All dimensions in inches1. Ordering and material as per code shown in Figure F.6.2. All working surfaces to have a maximum finish of 30 µin (arithmetic average).3. Stamp identification mark clearly—avoid working surfaces.4. Chemically clean caps—use a procedure to minimize oxidation and to be noninsulating in nature.5. To be used with Figure F.5 electrode adaptors only.

Table F.3MStandard for Increased Water Flow Male Cap Electrodes

Tolerance

EFGKPS

DiameterTaper diameterLengthHole diameterTaper locationSkirt length

19.014.332.011.22.3

15.7

±0.05+0.00/–0.03

±0.25±0.25±0.25±0.25

Notes: All dimensions in millimeters1. Ordering and material as per code shown in Figure F.6.2. All working surfaces to have a maximum finish of 0.75 µm (arithmetic average).3. Stamp identification mark clearly—avoid working surfaces.4. Chemically clean caps—use a procedure to minimize oxidation and to be noninsulating in nature.5. To be used with Figure F.5 electrode adaptors only.

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Use W for welding

Use C for cap

Use 1-2 for spotweld cap (female)

Nose configuration Use A for 45° truncated cone(Ref. Figure F.10) Use B for angle dressing only

Use C for contour dressingUse D for narrow flange widths

Material class Use 2 (Class 2 RWMA)(class numbers)

Cap diameter Use 5 for 0.62 in (15.7 mm) nominal diameter[in 0.12 in (3 mm) increments]

W C 1-2 B 2 5 Typical cap coding

Cap will be 0.62 in (15.7 mm) diameter


Cap will have A-dome nose

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

AWS D8.6:2005

65

Notes:1. For manufacture by cold forming only.2. Use RWMA Class 2 (M-1566-B) in annealed condition—After forming, age-harden for 5 hours at a temperature to produce a minimum

hardness of RB 77 measured within 0.12 of center line and 0.03 below surface of cap.3. Flat on welding face must be provided to give weld button sizes specified without exceeding weld indentation limitations.

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

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Notes:1. For manufacture by cold forming only.2. Use RWMA Class 2 (M-1566-B) in annealed condition—After forming, age-harden for 5 hours at a temperature to produce a minimum

hardness of RB 77 measured within 0.12 of center line and 0.03 below surface of cap.3. Flat on welding face must be provided to give weld button sizes specified without exceeding weld indentation limitations.

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

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67

Table F.4Standard for Female Cap Electrodes

Tolerance

EFGPST

DiameterTaper diameterLengthTaper locationTaper depthSpherical radius

0.6250.4580.8500.3540.3620.165

±0.002+0.000/–0.001

±0.010±0.010±0.010±0.010

Notes: All dimensions in millimeters1. Ordering and material as per code shown in Figure F.9.2. All working surfaces to have a maximum finish roughness of 30 µin (arithmetic average).3. Stamp identification mark clearly—avoid working surfaces.4. Chemically clean caps—use a procedure to minimize oxidation and to be noninsulating in nature.

Table F.4MStandard for Female Cap Electrodes

Tolerance

EFGPST

DiameterTaper diameterLengthTaper locationTaper depthSpherical radius

15.911.621.69.009.204.20

±0.05+0.03/–0.00

±0.25±0.25±0.25±0.25

Notes: All dimensions in millimeters1. Ordering and material as per code shown in Figure F.9.2. All working surfaces to have a maximum finish roughness of 30 µin (arithmetic average).3. Stamp identification mark clearly—avoid working surfaces.4. Chemically clean caps—use a procedure to minimize oxidation and to be noninsulating in nature.

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Use W for welding

Use B for adaptor

Use 1-2 for straight adaptor (female cap)

Adaptor shank Use T for tapered shank


Adaptor diameter Use 5 for 0.62 in (15.7 mm) nominal diameter[in 0.12 in (3.0 mm) increments)

Length Minimum length – 6 = 1.5 in (38 mm)[in 0.25 in (6.4 mm) increments]

W B 1-2 T 3 5 10 Typical adaptor coding

Adaptor will be 2.5 in (63 mm) long

Adaptor will have 0.62 in (15.7 mm) diameter



Adaptor will be straight for female cap

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

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

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

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70

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

Tolerance

AFYB

KLNPRTZX

DiameterTaper diameterTaper locationLengthLength, minimumHole diameterHole diameterTaper diameter cap endTape location cap endTaper lengthHole “K” lengthTaper diameterTaper locationsElectrode Cap

0.6250.6250.750

As coded1.5000.3120.3700.4720.1000.5000.6200.5010.380

Figure 20

±0.002+0.000/–0.001

±0.010±0.010

—±0.002±0.010

+0.001/–0.000±0.010±0.010±0.010

Ref.+0.000/–0.001

—

Notes: All dimensions in inches1. Ordering and material as per code shown in Figure F.11.2. All working surfaces to have a maximum finish roughness of 30 µin (arithmetic average).3. Stamp identification mark clearly—avoid working surfaces.4. Chemically clean caps—use a procedure to minimize oxidation and to be noninsulating in nature.

Table F.5MStandard for Straight Adaptors for Type “F” Female Cap Electrodes

Tolerance

AFYB

KLNPRTZX

DiameterTaper diameterTaper locationLengthLength, minimumHole diameterHole diameterTaper diameter cap endTape location cap endTaper lengthHole “K” lengthTaper diameterTaper locationsElectrode Cap

15.915.919.0

As coded38.07.929.4

11.992.5

12.715.812.79.65

Figure 20

±0.05+0.000/–0.03

±0.25±0.25

—±0.05±0.25

+0.002/–0.000±0.25±0.25±0.25Ref.

+0.00/–0.25—

Notes: All dimensions in millimeters1. Ordering and material as per code shown in Figure F.11.2. All working surfaces to have a maximum finish roughness of 0.75 µm (arithmetic average).3. Stamp identification mark clearly—avoid working surfaces.4. Chemically clean caps—use a procedure to minimize oxidation and to be noninsulating in nature.

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71

Annex G (Informative)

Female Cap Electrodes and Adaptor Conventions in Common Usage by Automotive Companies


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72

Figure G.1—Nomenclature for Straight Adaptors and Assembliesfor Female Cap Electrodes with RWMA #5 Taper

AWS D8.6:2005

73

Figure G.1M—Nomenclature for Straight Adaptors and Assembliesfor Female Cap Electrodes with RWMA #5 Taper

AWS D8.6:2005

74

Table G.1Standard for Straight Adaptor for Female Cap Electrodes

A B C D E Shank (Less Cap)

When Assembledwith MW6008 Cap

is Equivalent to

1.752.002.252.502.753.003.253.503.754.004.254.504.755.005.255.505.756.006.256.50

1.001.251.501.752.002.252.502.753.003.253.503.754.004.254.504.755.005.255.505.75

0.831.081.331.581.832.082.332.582.833.083.333.583.834.084.334.584.835.085.335.58

1.091.341.591.842.092.342.592.843.093.343.593.844.094.344.594.845.095.345.595.84

1.211.461.711.962.212.462.712.963.213.463.713.964.214.464.714.965.215.465.715.96

MW631-51MW631-52MW631-53MW631-54MW631-55MW631-56MW631-57MW631-58MW631-59MW631-60MW631-61MW631-62MW631-63MW631-64MW631-65MW631-66MW631-67MW631-68MW631-69MW631-70

RWMA-A227RWMA-A228RWMA-A229RWMA-A2210RWMA-A2211RWMA-A2212RWMA-A2213RWMA-A2214RWMA-A2215RWMA-A2216RWMA-A2217MW407-14AMW407-15A

———————


Table G.1MStandard for Straight Adaptor for Female Cap Electrodes

A B C D E Shank (Less Cap)


is Equivalent to

44.450.857.163.570.076.282.588.995.3

101.6107.9114.3120.6127.0133.3139.7146.0152.4158.7165.1

25.431.738.144.450.857.163.570.076.282.588.995.3

101.6107.9114.3120.6127.0133.3139.7146.0

21.127.433.840.146.552.859.265.571.978.284.590.997.3

103.6110.0116.3122.7129.0135.4141.7

27.734.140.446.853.159.565.872.278.584.891.297.6

103.9110.3116.6123.0129.3135.7141.7148.3

30.737.143.449.856.162.568.875.281.587.994.2

100.6106.9113.3119.6126.0132.3138.7145.0151.4

MW631-51MW631-52MW631-53MW631-54MW631-55MW631-56MW631-57MW631-58MW631-59MW631-60MW631-61MW631-62MW631-63MW631-64MW631-65MW631-66MW631-67MW631-68MW631-69MW631-70

RWMA-A227RWMA-A228RWMA-A229RWMA-A2210RWMA-A2211RWMA-A2212RWMA-A2213RWMA-A2214RWMA-A2215RWMA-A2216RWMA-A2217MW407-14AMW407-15A

———————

All dimensions in millimeters

AWS D8.6:2005

75


Figure G.2—Nomenclature for Straight Adaptors and Assembliesfor Female Cap Electrodes with RWMA #4 and #1 Special Tapers


Figure G.2M—Nomenclature for Straight Adaptors and Assembliesfor Female Cap Electrodes with RWMA #4 Cap and RWMA #4 Tapers

AWS D8.6:2005

76

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

A B C D E

RWMA #4 Tapered Shank #1 Speciala Tapered Shank

RWMA #4Tapered Shank

(Less Cap)


is Equivalent to

#1 SpecialTapered Shank

(Less Cap)


is Equivalent to

1.501.752.002.252.502.753.003.253.504.005.00

1.001.251.501.752.002.252.502.753.003.504.44

0.650.901.141.401.651.902.142.402.653.154.15

0.941.191.441.691.942.192.442.692.943.504.44

1.001.251.501.752.002.252.502.753.003.504.50

MW645-51MW645-52MW645-53MW645-54MW645-55MW645-56MW645-57MW645-58MW645-59MW645-61MW645-63

RWMA-A2160RWMA-A2170RWMA-A2180RWMA-A2190RWMA-A2110RWMA-A2111

—RWMA-A2113RWMA-A2114

——

MW6021-51—

MW6021-53—

MW6021-55—

MW6021-57—

MW6021-59——

MW6346-2B—

MW6346-4B—

MW6346-6B—

MW6346-8B————

aApproximately 6° taper. All dimensions in inches

Table G.2MStandard for Straight Adaptors for RWMA #4 Female Cap Electrodes and #1 Special Tapers

A B C D E

RWMA #4 Tapered Shank #1 Speciala Tapered Shank

RWMA #4Tapered Shank

(Less Cap)


is Equivalent to

#1 SpecialTapered Shank

(Less Cap)


is Equivalent to

38.144.450.857.163.570.076.282.588.9

101.6127.0

35.431.738.144.450.857.163.570.076.288.9

112.8

16.522.929.235.641.948.354.661.067.380.0

130.8

23.930.236.642.949.355.662.068.374.788.9

112.8

25.431.738.144.450.857.163.570.076.288.9

114.3

MW645-51MW645-52MW645-53MW645-54MW645-55MW645-56MW645-57MW645-58MW645-59MW645-61MW645-63

RWMA-A2160RWMA-A2170RWMA-A2180RWMA-A2190RWMA-A2110RWMA-A2111

—RWMA-A2113RWMA-A2114

——

MW6021-51—

MW6021-53—

MW6021-55—

MW6021-57—

MW6021-59——

MW6346-2B—

MW6346-4B—

MW6346-6B—

MW6346-8B————

aApproximately 6° taper. All dimensions in millimeters

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Figure G.3—Nomenclature for Straight Adaptors and Capsfor Female Cap Electrodes with RWMA #6 Taper


Figure G.3M—Nomenclature for Straight Adaptors and Capsfor Female Cap Electrodes with RWMA #6 Taper

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78

Table G.3Standard for Straight Adaptors for RWMA #6 Female Cap Electrodes

A B Cap Code No.

2.382.382.882.883.383.383.633.883.884.134.384.384.634.884.885.385.885.885.886.386.38

1.501.502.002.002.502.502.753.003.003.253.503.503.754.004.004.504.505.005.005.505.50

MW6008MW6146MW6146MW6008MW6146MW6008MW6146MW6146MW6008MW6146MW6008MW6146MW6146MW6008MW6146MW6008MW6146MW6008MW6146MW6008MW6146

MW983-530MW1121-53MW1121-55MW983-550MW1121-57MW983-570MW1121-58MW1121-59MW983-590MW1121-60MW983-610MW1121-61MW1121-62MW983-630MW1121-63MW983-650MW1121-65MW983-670MW1121-67MW983-690MW1121-69


Table G.3MStandard for Straight Adaptors for RWMA #6 Female Cap Electrodes

A B Cap Code No.

60.460.473.273.285.985.992.298.698.6

104.9111.3111.3117.6124.0124.0136.7136.7149.3149.3162.1162.1

38.138.150.850.863.563.570.076.276.282.588.988.995.3

101.6101.6114.3114.3127.0127.0139.7139.7

MW6008MW6146MW6146MW6008MW6146MW6008MW6146MW6146MW6008MW6146MW6008MW6146MW6146MW6008MW6146MW6008MW6146MW6008MW6146MW6008MW6146

MW983-530MW1121-53MW1121-55MW983-550MW1121-57MW983-570MW1121-58MW1121-59MW983-590MW1121-60MW983-610MW1121-61MW1121-62MW983-630MW1121-63MW983-650MW1121-65MW983-670MW1121-67MW983-690MW1121-69


AWS D8.6:2005

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All dimensions except degrees in inches

Figure G.4—Nomenclature for Female Electrode Caps

AWS D8.6:2005

80

All dimensions except degrees in millimeters

Figure G.4M—Nomenclature for Female Electrode Caps

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H1. IntroductionThe American Welding Society (AWS) Board of Directorshas adopted a policy whereby all official interpretationsof AWS standards are handled in a formal manner.Under this policy, all interpretations are made by thecommittee that is responsible for the standard. Officialcommunication concerning an interpretation is directedthrough the AWS staff member who works with thatcommittee. The policy requires that all requests for aninterpretation be submitted in writing. Such requests willbe handled as expeditiously as possible, but due to thecomplexity of the work and the procedures that must befollowed, some interpretations may require considerabletime.

H2. ProcedureAll inquiries shall be directed to:

Managing DirectorTechnical Services DivisionAmerican Welding Society550 N.W. LeJeune RoadMiami, FL 33126

All inquiries shall contain the name, address, and affilia-tion of the inquirer, and they shall provide enough infor-mation for the committee to understand the point ofconcern in the inquiry. When the point is not clearlydefined, the inquiry will be returned for clarification. Forefficient handling, all inquiries should be typewritten andin the format specified below.

H2.1 Scope. Each inquiry shall address one single provi-sion of the standard unless the point of the inquiryinvolves two or more interrelated provisions. The provi-sion(s) shall be identified in the scope of the inquiry

along with the edition of the standard that contains theprovision(s) the inquirer is addressing.

H2.2 Purpose of the Inquiry. The purpose of theinquiry shall be stated in this portion of the inquiry. Thepurpose can be to obtain an interpretation of a standard’srequirement or to request the revision of a particularprovision in the standard.

H2.3 Content of the Inquiry. The inquiry should beconcise, yet complete, to enable the committee to under-stand the point of the inquiry. Sketches should be usedwhenever appropriate, and all paragraphs, figures, andtables (or annex) that bear on the inquiry shall be cited. Ifthe point of the inquiry is to obtain a revision of thestandard, the inquiry shall provide technical justificationfor that revision.

H2.4 Proposed Reply. The inquirer should, as aproposed reply, state an interpretation of the provisionthat is the point of the inquiry or provide the wording fora proposed revision, if this is what inquirer seeks.

H3. Interpretation of Provisions of the Standard

Interpretations of provisions of the standard are made bythe relevant AWS technical committee. The secretary ofthe committee refers all inquiries to the chair of the par-ticular subcommittee that has jurisdiction over the por-tion of the standard addressed by the inquiry. Thesubcommittee reviews the inquiry and the proposed replyto determine what the response to the inquiry shouldbe. Following the subcommittee’s development of theresponse, the inquiry and the response are presented tothe entire committee for review and approval. Uponapproval by the committee, the interpretation is an official

Annex H (Informative)

Guidelines for the Preparation of Technical InquiriesThis annex is not a part of AWS D8.6:2005, Specification for Automotive Resistance

Spot Welding Electrodes, but is included for informational purposes only.

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interpretation of the Society, and the secretary transmitsthe response to the inquirer and to the Welding Journalfor publication.

H4. Publication of InterpretationsAll official interpretations will appear in the WeldingJournal and will be posted on the AWS web site.

H5. Telephone InquiriesTelephone inquiries to AWS Headquarters concerningAWS standards should be limited to questions of a gen-eral nature or to matters directly related to the use of thestandard. The AWS Board of Directors’ policy requiresthat all AWS staff members respond to a telephonerequest for an official interpretation of any AWS stan-dard with the information that such an interpretation can

be obtained only through a written request. Headquartersstaff cannot provide consulting services. However, thestaff can refer a caller to any of those consultants whosenames are on file at AWS Headquarters.

H6. AWS Technical Committees

The activities of AWS technical committees regardinginterpretations are limited strictly to the interpretation ofprovisions of standards prepared by the committees or toconsideration of revisions to existing provisions on thebasis of new data or technology. Neither AWS staff northe committees are in a position to offer interpretive orconsulting services on (1) specific engineering problems,(2) requirements of standards applied to fabricationsoutside the scope of the document, or (3) points notspecifically covered by the standard. In such cases, theinquirer should seek assistance from a competent engi-neer experienced in the particular field of interest.

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List of AWS Documents on Automotive Welding

Designation Title

D8.6 Specification for Automotive Resistance Spot Welding Electrode

D8.7M Recommended Practices for Automotive Weld Quality—Resistance Spot Welding

D8.8 Specification for Automotive Frame Welding Quality—Arc Welding

D8.9M Recommended Practices for Test Methods for Evaluating the Resistance Spot Welding Behaviorof Automotive Sheet Steel Materials

D8.14M Specification for Automotive and Light Truck Components Arc Welding—Aluminum


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AWS D8.6:2005

Specification for Automotive Resistance Spot Welding ...

Documents

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