Forming and re-forming welding electrodes with contoured faces

摘要

A method is disclosed for using welding electrodes with a spherically-domed welding face having concentric contoured features formed into the face for better contact with workpiece surfaces. The concentric contoured features may be initially formed by rotating a cutting tool with a contoured cutting edge, the cutting edge being in engagement with the electrode face. A similar practice may be followed to re-create the weld face surface geometry if it becomes eroded or malformed during welding use. A suitable tool may have a blade-like geometry, with a mounting portion for supporting and positioning the tool in a rotating holder and a cutting edge. The cutting edge may have a contour complementary to that of the weld face and extend at least from the center of the weld face to at least the radial extent of the concentric contoured features.

主权项

1. A method of using an electrode in electrical resistance welding, the method comprising:
providing an electrode that comprises a spherically-domed weld face for contact of the spherically-domed face with a workpiece in an electrical resistance welding operation, the weld face comprising concentric circular rings of ridges that project outwardly from the spherical dome of the weld face, each of the circular rings of ridges being uninterrupted around its circumference, and the material of the spherically-domed weld face being susceptible to degradation in welding operations; contacting the spherically-domed weld face of the electrode with one or more workpieces to form electrical resistance welds; determining when the concentric circular rings of ridges projecting from the spherically-domed weld face have been degraded for suitable electrical contact with a workpiece; engaging the spherically-domed weld face with a cutter blade of a cutting tool, the cutter blade having a cutting surface that has recessed surfaces extending across the cutting surface, and wherein the circular rings of ridges are received in the recessed surfaces of the cutting surface of the cutting blade; rotating the cutting tool around the spherically domed weld face while the cutting surface of the cutter blade is engaged with the weld face to cut the weld face and remove material from the concentric circular rings of ridges and base surfaces of the weld face that separate the concentric circular rings of ridges; and, thereafter continuing to form welds with the electrode.