Resistance Welding Electrodes: Do's and Don'ts Category: Knowledge DO's DON'T Use standard electrodes wherever possible. Avoid special, offset or irregular tips when the job can be done with a standard straight tip. Use the most suitable tip diameter for the thickness of stock being welded. Don't use small tips on heavy gauge welding jobs or large tips on small work. Use open sight drains to observe more readily the water flow through the holders. Don't forget to turn on the cooling water full force before starting to weld. Connect the water inlet hose to the proper holder inlet so that the water flows through the center cooling tube first. Never use water hose that will not fit the holder water connection nipples snugly. Internally cool the spot welding tips with cool water flowing at a rate of at least 2 liter per minute through each tip. Do not allow water connections to become leaky, clogged or broken. Be sure the internal water cooling tube of the holder projects into the tip water hole to within 6mm of the tip hole bottom. Avoid using holders with leaking or deformed tapers. Adjust the internal water cooling tube of the holder to the proper height when changing to a different length tip. Never use electrode holders that do not have an adjustable internal water cooling tube. Be sure top of adjustable water cooling tube in holders is cut at an angle so as to avoid jamming tip down and shutting water off. Do not permit adjustable water tube to be "frozen" by accumulation of deposits. A few drop of oil periodically will keep the tube free. place a thin film of cup grease on the tip taper prior to inserting in the holder, to make it easier to remove. Do not allow electrodes to remain idle in tapered holder seats for extended periods. Use ejector type holders for easy removal of tips and to avoid damage to tip taper. Don't use pipe wrenches or similar tools in removing electrodes. Keep the tip taper and holder taper clean, smooth and free of foreign deposits. Avoid using white lead or similar compounds to seal a leaking taper. Dress spot welding electrodes frequently to maintain the quality of the welds. Never permit a spot welding tip to mushroom enough to make dressing difficult. Dress electrodes in a lathe to their original contour whenever possible. Never dress electrodes with a coarse file. Use a rawhide or rubber mallet for striking holder or tips in aligning operations. Don't pound on the holder or tip with a steel hammer in aligning the welder arms. Provide flood cooling on both sides of seam welding wheel. Avoid the use of seam welder wheels too thin to stand the heat or pressure of your job. Use properly designed knurling wheels to maintain proper seam welding wheel shape. Do not permit seam welding wheel to run off the corners of the work being welded.