The introduction of galvanized steels into automotive manufacturing has posed new challenges to resistance welding practices. Coated steels have gained considerable interest due to the commitment of producers to increase corrosion resistance. The zinc coating has proven to have adverse affects on the performance of the electrodes contributing to premature wear, sticking and increased maintenance and power utilization. As a result, traditional welding with chrome and/or chrome zirconium electrodes has become inefficient and costly with considerable production downtime.

Galvanized steel products have been utilized by automotive manufacturers in other parts of the world for better than ten years. Automobile & Two wheeler Manufacturers were changing to coated sheets due to prevailing corrosion problems which existed in using bare metal. Refinements in coating processes, in conjunction with the utilization of new resistance welding materials has enabled the industry to dramatically increase their welding efficiency during the past decade. At this time, most of the North American automotive industry has elected to use welding products produced from either Aluminum Oxide Dispersion Strengthened Copper.

The dispersion strengthened copper is primarily designed for applications requiring the highest electrical and thermal conductivities along with good elevated temperature strength. The dispersion strengthened copper has excellent cold working characteristics, and can be drawn into fine wire or rolled into thin sheets.

The dispersion strengthened copper is recommended for hybrid circuit package components; vacuum tube, microwave tube, and X-ray tube components such as anodes, grids, cathodes, helixes, and heat sinks; electrical components such as circuit breakers, relay blades, and switches, rotating equipment components such as commutators, electric generator and motor components, and brush springs; and high power magnet windings.

The dispersed Al2O3 is thermally stable so that it acts to retard re-crystallization of the copper. Consequently, significant softening does not occur as the result of high temperature exposure. Along with superior strength retention, thermal and electrical conductivities are higher than conventional copper alloys.

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