How Does Water Temperature Affect Your Electrode Life?
Practical guide on cooling in resistance welding
One of the most frequent questions we receive at ALCAVIL is: "Why do my electrodes wear out so quickly?" In many cases, the answer isn't in the electrode material, but in something that seems trivial: cooling water temperature. A poorly configured cooling system can reduce electrode life by up to 50%.
The Hot Water Problem
When cooling water is too hot, several negative things happen simultaneously:
The electrode "mushrooms" (deforms like a mushroom) more rapidly. An electrode that normally grows 10% in diameter can grow up to 40% with hot water in the same number of welds.
Welds made with inadequate cooling have lower mechanical strength. In destructive testing, the loss can reach up to 35% compared to welds made with proper cooling.
The electrode copper alloys more rapidly with zinc from galvanizing or aluminum from coatings. This degrades electrode conductivity and causes sticking.
Flow Also Matters
It's not enough to have cold water; you also need sufficient flow. The minimum recommendation is 1.5 GPM (gallons per minute) per electrode, equivalent to approximately 5.7 liters per minute.
Comparison: Adequate vs Inadequate Cooling
| Parameter | Optimal Cooling | Inadequate Cooling |
|---|---|---|
| Water temperature | 13-16°C (55-60°F) | >32°C (>90°F) |
| Flow per electrode | ≥1.5 GPM (5.7 L/min) | <0.5 GPM (1.9 L/min) |
| Diameter growth | ~10% per dress | ~40% per dress |
| Relative life | 100% | 50-60% |
Practical Recommendations
Monitor Your Chiller
Check daily that water temperature is within optimal range. A thermometer in the return line will give you valuable information.
Verify Flow
Use a flow meter or at least visually verify that water is flowing with good pressure. Clogged lines reduce flow without you noticing.
Circuit Maintenance
Clean the internal channels of electrode holders periodically. Sediment buildup reduces heat transfer and effective flow.
Consider the Environment
In summer or in plants without climate control, the chiller works harder. Verify it has sufficient capacity to maintain temperature.
Need advice on your cooling system?
Our engineering team can help you optimize electrode life.