Spot Welding Supplies - Seam Welding Wheels

SCI distributes individually upset-forged and heat-treated seam welding wheels, tube mill electrodes, plate and bar. Most products are available from inventory, or can be custom made to meet your specific needs.

Forged electrodes are available -- either forged and heat treated-only, or fully machined-to-print -- in RWMA Class 2, 2-premium, 3 and 4 materials. Click on Resistance Welding Copper Alloys for details and availability.

There is a direct relationship between production down-time and the method of manufacture of seam welding wheels (resistance welding electrodes). Individually upset-forged welding wheels outperform cast wheels every time, making them the clear choice for extending electrode life. Many RWMA suppliers do not understand the importance of, and do not supply, individually forged wheels.

Why upset-forged seam welding wheels perform better, last longer...

  • Individually upset-forged seam welding wheels increase production up-time and enhance weld performance because of their fine equiaxed grain microstructures.
  • Fine radial grain flow, the essential property for minimizing premature edge deformation, can only be produced by the upset forging process. Each wheel must be individually forged and heat treated to develop this advantageous microstructure.
  • Cast wheels, produced without forging, have large columnar grain structures that contribute to edge chipping and flaking, unreliable performance and higher production costs.

How to tell them apart...

  • Forged and cast wheels look alike and have similar hardness and electrical conductivity properties. On the surface it's hard to tell them apart. But, when the surfaces of both wheels are chemically etched, the difference in grain structure is revealed.
  • Upset-forged wheels (Photo 1)
    The surface of the lower wheel is etched, revealing the fine grain structure that ensures reliable performance.
  • Cast wheels (Photo 2)
    The lower wheel, which is etched, reveals the inherent weakness of cast wheels -- large, columnar grain structure that results in chipping, flaking and unreliable performance.

Process Certification...

Every wheel we produce is individually forged and heat treated. Each customer job is internally certified under our quality system of process verification. Certification is essential to ensure that your wheels are individually forged.

If the wheels you're currently using are performing poorly, ask your supplier to certify method of manufacture. Suppliers sometimes do mix wheels. If you're not satisfied, we'll gladly test them for structural form.

Individually Upsed Forged Welding Wheels
(1) Individually upsed forged welding wheels.
Lower wheel is etched, revealing the fine grain structure that ensures reliable performance.


Cast Wheels
(2) Cast Wheels.
Upper wheels look like an upset-forged wheel. But, after an etch test, the lower cast wheel reveals the large, columnar grain structure that results in chipping, flaking, unreliable performance - all adding up to higher production costs!

Spotwelding Consultants Inc.

4209 Industrial
Rowlett, Texas 75088
Toll Free: 888-255-6780
Phone: 972-475-0874
Fax: 972-475-5024