Electrode Sticking During Micro-Resistance Welding of Thin Metal Sheets

The electrode sticking mechanism and factors affecting the sticking, including welding current, weld time, electrode tip coating, electrode force and electrode spacing, were studied during micro-resistance welding of very thin nickel-plated steel to nickel sheets in the assembly of a cell-phone battery package. The results indicated that electrode sticking was caused by local metallurgical bonding between the electrode and the nickel-plated steel sheet. The sticking force was proportional to the total area of the local bonds and to the bonding strength between the electrode and sheet. Reducing welding current and weld time, and increasing electrode force and electrode spacing were found to reduce electrode sticking. Welding electrodes with tips coated with TiC metal matrix composite were tried as an alternative to the regular CuCrZr electrode and were found to be more resistant to sticking.