Technical Parameters
Parameter | Details |
Product Name | Head diameter 0.5mm tungsten-copper 80% electrode |
Material | Tungsten-copper 80 (80% tungsten, 10% copper) |
Dimensions | 65*6*0.5mm |
Manufacturing Process | Mechanical processing |
Dimensional Tolerance | Compliant with custom drawings and national standards |
Usage Method | Lap welding (upper-lower welding) |
Arc Stability | ≤±0.1A current fluctuation |
Heat Dissipation Efficiency | 20% higher than pure tungsten electrodes |
Product Features
Premium Tungsten-Copper 80 Alloy Composition
The electrode is made of tungsten-copper 80 alloy, a perfect blend of tungsten’s high-temperature resistance and copper’s electrical conductivity. This combination ensures stable arc ignition and rapid heat dissipation, preventing electrode overheating during prolonged welding.
0.5mm Ultra-Fine Head Diameter
The ultra-small 0.5mm head diameter allows precise targeting of small welding joints and thin workpieces (0.1-1.0mm thickness). It minimizes heat-affected zones, avoiding workpiece deformation and ensuring weld seam precision.
High-Precision Mechanical Processing
Advanced mechanical processing technology achieves micron-level dimensional accuracy. The electrode’s head is polished to a smooth finish, reducing arc wandering and ensuring consistent current distribution during lap welding.
Lap Welding Optimization
Tailored for lap welding (upper-lower welding), the electrode’s structural design ensures tight contact with overlapping workpieces. It maintains stable performance even when welding dissimilar metals (e.g., steel-copper, aluminum-steel).
Compliance with Strict Standards
Every electrode undergoes rigorous inspection to meet national welding material standards and custom drawing requirements. Its dimensional tolerance is controlled within ±0.02mm, ensuring interchangeability and reliability.
Applications
Aerospace Precision Components
Used for welding small aerospace parts such as sensor housings, connector pins, and lightweight structural components. The ultra-fine head diameter meets the miniaturization requirements of aerospace manufacturing.
Precision Instrument Manufacturing
Ideal for welding precision instruments (e.g., medical devices, measuring tools) where weld seam size and accuracy directly affect product functionality. The tungsten-copper alloy avoids contamination of sensitive instrument parts.
Electronic Connector Production
Suitable for welding microelectronic connectors, circuit board pads, and battery terminals. The stable arc and small heat-affected zone protect delicate electronic components from damage.
Medical Device Assembly
Applied in manufacturing medical devices (e.g., surgical instruments, implantable components) that require biocompatible and precise welds. The pure material composition ensures no toxic emissions during welding.
Projection Welding Process
Workpiece Alignment
Align the overlapping workpieces accurately, ensuring the welding joint is centered under the electrode’s 0.5mm head. Use positioning jigs to avoid displacement during welding.
Electrode Installation
Mount the tungsten-copper 80 electrode onto the upper-lower welding equipment. Adjust the electrode height to maintain a 0.1-0.3mm gap between the head and workpiece surface for optimal arc ignition.
Parameter Configuration
Set the welding current (80-200A) and welding time (0.3-1.5s) based on workpiece thickness and material. The tungsten-copper alloy’s conductivity allows for lower current settings, reducing workpiece deformation.
Lap Welding Execution
Initiate the welding cycle; the electrode’s ultra-fine head delivers concentrated heat to the joint. Monitor the arc duration and current stability to ensure complete fusion of the overlapping layers.
Post-Welding Finishing
Remove any minor spatter with a soft brush (avoid harsh cleaning to prevent workpiece damage). Inspect the weld seam for uniformity and adhesion— the electrode’s design ensures minimal post-processing needs.
Customization Services
Our customization services cater to specialized production requirements:
Adjust the 0.5mm head diameter (range: 0.3-1.0mm) to fit different joint sizes.
Modify overall dimensions (length, width, thickness) according to custom technical drawings.
Customize tungsten-copper alloy ratios (85/15 to 95/5) for specific conductivity or temperature resistance needs.
Provide small-batch customization for prototype development and mass production support.
Ensure all customized products meet ISO welding material standards and quality certifications.
Frequently Asked Questions (FAQ)
1. What advantages does tungsten-copper 80 alloy offer over pure tungsten?
Tungsten-copper 90 combines tungsten’s high-temperature resistance with copper’s superior conductivity and heat dissipation, making it ideal for precision lap welding of thin or sensitive workpieces.
2. Can the 0.5mm head diameter handle thick workpieces?
The electrode is optimized for thin workpieces (0.1-1.0mm). For thicker materials (＞1.0mm), we recommend customizing the head diameter to 0.8-1.0mm for better heat distribution.
3. Is the electrode suitable for automated welding lines?
Yes, its precise dimensions and stable performance make it compatible with automated lap welding equipment, supporting high-speed mass production.
