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Catalog 2017TUFFALOYResistance Welding ProductsLeader in the Industry Since 1937Master DistributorPRODUCTION ENGINEERING(888) nceweldsupplies.com
TUFFALOY table of contentsSTANDARD ELECTRODESWELDING ELECTRODE HOLDERS(continued)Straight Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Paddle-Type Holders . . . . . . . . . . . . . . . . . . . 27TUFFCAP Caps and Shanks . . . . . . . . . . . . . . . 7Platen-Mounted Holders . . . . . . . . . . . . . . . . 30Standard Bent Electrodes . . . . . . . . . . . . . . . 10Fast-Follow-Up Holders . . . . . . . . . . . . . . . . . 41Miscellaneous Electrodes . . . . . . . . . . . . . . . 13HIGH PRESSURE WELDINGBack Up Electrodes . . . . . . . . . . . . . . . . . . . . 14Electrodes and Holders . . . . . . . . . . . . . . . . . 28Swivel Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . 15NUT AND STUD WELDINGRefractory Metal-Faced Tips . . . . . . . . . . . . . . 15Nut Welding Electrodes . . . . . . . . . . . . . . . . . 31Threaded Electrodes . . . . . . . . . . . . . . . . . . . 16Nut Welding Electrode Holders . . . . . . . . . . . 31Platen Mount Nut and Stud Holders . . . . . . . . . 31WELDING ELECTRODE HOLDERSElectrode Adapters . . . . . . . . . . . . . . . . . . . . . 17Artic Nut and Stud WeldingWater Cooled Holders . . . . . . . . . . . . . . . . . . 32Cylinder-Mounted Holders . . . . . . . . . . . . . . . 18Metric Nut Electrode Systems . . . . . . . . . . . 33Multi-Spot Barrel and Clamp . . . . . . . . . . . . . 19GH Series Nut Welding Head . . . . . . . . . . . . 34Straight Holders . . . . . . . . . . . . . . . . . . . . . . . 20Stud and Backup Welding Electrodes . . . . . . . . . 35Offset Holders . . . . . . . . . . . . . . . . . . . . . . . . 24Welder Arms . . . . . . . . . . . . . . . . . . . . . . . . . . 24Variable-Offset Holders . . . . . . . . . . . . . . . . . 26X2Visit www.tuffaloyproducts.com for updated product listings
TUFFALOY table of contentsMULTIPLE WELDINGACCESSORIES(continued)Teeter Tip Adapters . . . . . . . . . . . . . . . . . . . . 36TUFFCAP Extractors . . . . . . . . . . . . . . . . . . . . 45Equatip Dual Tip Holders . . . . . . . . . . . . . . . 37Quick Connect Couplings . . . . . . . . . . . . . . . 45Equa-Press Dual Tip Holders . . . . . . . . . . . . 38Conductive Lube . . . . . . . . . . . . . . . . . . . . . . . 45Trispacer Triple Tip Holder . . . . . . . . . . . . . . 40Water Hose and Clamps . . . . . . . . . . . . . . . . 45Weld Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . 46RESISTANCE WELDING ALLOYSWelder Arms . . . . . . . . . . . . . . . . . . . . . . . . . . 24Weld Force Gauges . . . . . . . . . . . . . . . . . . . . 48Bar Stock . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Pneumatic Electrode Dresser . . . . . . . . . . . . 50Refractory Metals and Forgings . . . . . . . . . . 43Seam Welding Wheels and Forging . . . . . . . . 43Welding Data . . . . . . . . . . . . . . . . . . . . . . . . . . 51Helpful Data Suggestions . . . . . . . . . . . . . . . 59ACCESSORIESShunts and Cables . . . . . . . . . . . . . . . . . . . . 44Stationary Water Tubes . . . . . . . . . . . . . . . . . 18Electrode Taper Reamers, Tapand TUFFCAP Taper Reamers . . . . . . . . . . . . 45Tip Dressing Tool . . . . . . . . . . . . . . . . . . . . . . 45Radius File . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Welding Tip Extractors . . . . . . . . . . . . . . . . . . 45Special & Custom Parts available, contact us for a quotation (888) 654-93533
TUFFALOY standard straight tipsCCStraight tips from TUFFALOY are distinguished fortheir high conductivity and resistance to deformation,which are the two major requirements of resistancewelding tips. Modern manufacturing methods andconstant scientific quality control make the difference,starting with the alloying of pure copper, through barextrusion, and the conversion of this high-quality barstock into welding tips.BBATUFFALOY ensures conformity to all standarddimensions. Before shipment, all tips must passinspection by gage for uniform length, taper, andoutline of point.AEE1/21/2FDFD‘B’ DOME NOSE‘A’ POINTED NOSERWMA CLASS 1ACDEFOverall WeIding Gauging Water Hole Water HoleLength Face Dia. Dia.DepthDia.BNose DescriptionLengthRWMA CLASS 1RWMA CLASS 2PartNo.DescriptionPartNo.BNose DescriptionLengthRWMA CLASS 2PartNo.DescriptionPartNo.NO. 4 RW TAPER - 1/2” 716NO. 5 RW TAPER - 5/8” /41-1/21-3/422-1/42-1/22-3/433-1/4NO. 6 RW TAPER - 3/4” 731.731.7311-1/41-3/42-1/42-3/43-1/4NO. 7 RW TAPER - 7/8” 4.844.844.8441-1/41-3/42-1/42-3/43-1/2Visit www.tuffaloyproducts.com for updated product listings
standard straight tips TUFFALOYCC30 The bright shiny look of TUFFALOY tips is the resultof a passivation process that eliminates excessiveoxidation. It reflects the deep-down quality built intothese tips and into all TUFFALOY products.Only RWMA Class 1 (TUFFALOY 88) and Class 2(TUFFALOY 77) tips are listed here. Class 3 alloy(TUFFALOY 55) tips are also available. Forrecommended uses of these alloys, see page 49.AAETo order Class 3 alloy tips, change description codeto indicate it: see “Key to Description”, page 6.E1/21/2FDFD‘D’ OFFSET NOSE‘C’ FLAT NOSERWMA CLASS 1AOverallLengthDGaugingDia.EWater HoleDepthFWater HoleDia.CWelding DescriptionFace Dia.45 ONTIPS 1-1/4OR LESS INLENGTHRWMA CLASS 1RWMA CLASS 2PartNo.DescriptionPartNo.CWelding DescriptionFace Dia.RWMA CLASS 2PartNo.DescriptionPartNo.NO. 4 RW TAPER - 1/2” 138-2712138-2714138-2716NO. 5 RW TAPER - 5/8” . 6 RW TAPER - 3/4” 42-1/42-3/43-1/4NO. 7 RW TAPER - 7/8” 42-1/42-3/43-1/2Special & Custom Parts available, contact us for a quotation (888) 654-93535
TUFFALOY standard straight tipsTAPER ENGAGEMENTTIP SIZE4 RW5 RW6 RW7 RWCLENGTH1/2-in.3/4-in.7/8-in.1-1/8-in.R45 AKEY TO DESCRIPTIONNose DesignationRWMAAlloy ClassAEE-2-5-10E1/2RW Taper No.Length, in Number of 1/4-in. increments1/2FDFD‘F’ RADIUS FACED‘E’ TRUNCATED CONERWMA CLASS 1AOverallLengthDGaugingDia.EWater HoleDepthFWater HoleDia.CWelding DescriptionFace Dia.RWMA CLASS 1RWMA CLASS 2PartNo.DescriptionPartNo.RNose DescriptionRadiusRWMA CLASS 2PartNo.DescriptionPartNo.NO. 4 RW TAPER - 1/2” -1608E 710141-1712141-1714141-1716F 12141-2714141-2716NO. 5 RW TAPER - 5/8” . 6 RW TAPER - 3/4” 42-1/42-3/43-1/4NO. 7 RW TAPER - 7/8” /42-1/42-3/43-1/2Visit www.tuffaloyproducts.com for updated product listings
caps and shanks TUFFALOYTuffcap electrodes consist of two pieces: a shank anda replaceable cap. These two-part electrodes can offermajor economies, because when the nose geometry isworn out, only the cap needs to be replaced. And it costsfar less than a standard one-piece electrode. (A Tuffcapshank will normally outlast twenty caps.) Also, electrodeinventory can be kept small because all nose designswill fit the same size shank.TWO TYPES: TUFFALOY offers two kinds of Tuffcapelectrodes. One uses a male cap that fits into the shank.The other has a female cap that fits over the shank.FEMALE AND MALE CAPS are available in the widestrange of sizes, alloys, and styles. They are made in bothClass 1 and Class 2 alloy, and in sizes to fit- shanks sized4 through 7 RW. Male caps are more effectively cooledthan female caps.Female Cap TypeElectrode AssemblyMale Cap TypeElectrode AssemblyALL CAPS are made with the same nose designs inconformance with RWMA standards.SHANKS are made of Class 2 alloy, either straight,or bent to provide an offset. Shanks other than thosecataloged can be special ordered. Tuffcap, caps andshanks should be used only in a directly opposed,straight-line manner. They do not work as well asstandard electrodes on heavily coated metal suchas galvanized or tin-plate.TUFFTRODE-Z CAPS FOR COATED STEELSSize 5 RW straightand offset style shanksholding male type capswith swivel heads.These caps are catalogedon pages 8 & 15.To avoid electrode sticking problems common whenwelding galvanized and aluminized materials, thesecopper chrome-zirconium alloy caps are offered. Theygive the same performance as dispersion-strengthenedcaps but cost far less. They are Class 2 caps inmechanical and physical properties.Both male and female caps are offered in all the standardnose designs.Special & Custom Parts available, contact us for a quotation (888) 654-93537
TUFFALOY caps and shanksMALE CAPSSTRAIGHT SHANKS FOR MALE CAPS (CLASS 2*)Shank AssembledLengthLengthSHANKS 4 RW TAPERSHANKS 5 RW TAPERSHANKS 6 RW 161-2610161-2612POINTED TIPS ‘A’DOME TIPS ‘B’SHANKS 7 RW TAPER1-1/222-1/23‘E’ NOSE4 AND 5 6161-2708161-2710161-2712‘F’ NOSE4 AND 5 CAPFLAT TIPS ‘C’BENT SHANKS FOR MALE CAPS (CLASS 2*)Shank OffLength setSHANKS 4 RW TAPER2-1/2 1/22-1/2 3/42-1/2131/231-1/43-1/413-1/4 2-2450162-2460162-2470162-2480OFFSET TIPS ‘D’SHANKS 5 RW TAPER2-1/4 1/42-1/2 1/22-1/2 3/42-1/2131/231-1/43-1/413-1/4 162-2560162-2570162-2580* Class 3 Available8Visit www.tuffaloyproducts.com for updated product listingsTaper ofAlloy Adapter DescripClass ShanktionPartNo.1234RW4RW4RWTA-14 111-0014TA-24 112-0024TA-34 RW6RWTA-16 111-0016TA-26 112-0026127RW7RWTA-17 111-0017TA-27 112-0027124RW4RWTB-14 113-0014TB-24 114-0024125RW5RWTB-15 113-0015TB-25 114-0025126RW6RWTB-16 113-0016TB-26 114-0026127RW7RWTB-17 113-0017TB-27 114-00271234RW4RW4RWTC-14 115-0014TC-24 116-0024TC-34 122-30341235RW5RW5RWTC-15 115-0015TC-25 116-0025TC-35 122-3035126RW6RWTC-16 115-0016TC-26 116-0026127RW7RWTC-17 115-0017TC-27 116-00271234RW4RW4RWTD-14 117-0014TD-24 118-0024TD-34 122-40341235RW5RW5RWTD-15 117-0015TD-25 118-0025TD-35 122-4035126RW6RWTD-16 117-0016TD-26 118-0026127RW7RWTD-17 117-0017TD-27 118-0027111-0015126-0025112-0025122-1035
caps and shanks TUFFALOYFEMALE CAPSSTRAIGHT SHANKS FOR FEMALE CAPS (CLASS 2*)SHANKS 4 RW TAPERShank Assembled DescripLengthLengthtionSHANKS 5 RW TAPERSHANKS 6 RW 3-2612Taper ofAlloy Adapter DescripClass ShanktionPOINTED TIPS ‘A’24RW TP-24A 125-02412 (Cu Cr Zr) 4RW TP-24AZ 126-0241.84025RW TP-25A 125-02512 (Cu Cr Zr) 5RW TP-25AZ 126-025126RW TP-26A 125-02612 (Cu Cr Zr) 6RW TP-26AZ 126-0261DOME TIPS ‘B’24RWTP-24B 125-024225RW2 (Cu Cr Zr) 5RWTP-25B 125-0252TP-25BZ 126-025225RW2 (Cu Cr Zr) 5RWTP-25B-.20 125-0252.20TP-25BZ-.20 126-0252.2026RW2 (Cu Cr Zr) 6RWTP-26B 125-0262TP-26BZ 126-0262.840‘F’ NOSE4 AND 5 CAP3/16‘E’ NOSE4 AND 5 CAP9/32For improved cooling, female shanks are drilled through(to put water in contact with cap). Shanks may be orderedwith a blind water hole, upon request.FLAT TIPS ‘C’BENT SHANKS FOR FEMALE CAPS (CLASS 2*)2Shank OffLength setSHANKS 4 RW TAPER2-3/4 1/22-3/4 3/42-3/413-1/4 1/23-1/4 3-20TP-2414-16PartNo.ItemNo.4RWTP-24C 80164-249025RW TP-25C 125-02532 (Cu Cr Zr) 5RW TP-25CZ 126-025326RWTP-26C 125-026324RWTP-24D 125-0244OFFSET TIPS ‘D’SHANKS 5 RW TAPER2-3/4 1/22-3/4 3/42-3/413-1/4 1/23-1/413-1/4 542164-2545164-2547164-2565164-2570164-258025RW TP-25D 125-02542 (Cu Cr Zr) 5RW TP-25DZ 126-025426RWTP-26D 125-0264* Class 3 AvailableSpecial & Custom Parts available, contact us for a quotation (888) 654-93539
TUFFALOY bent tipsDOUBLE-BEND, WITH STANDARD NOSE DESIGNSThese standard cold-formed tips are bent from straight tips (some after added machining) and have the same hardnessand conductivity. They outlast, many times over, the old cast and forged tips of similar geometry, which are impossible tocool adequately.The table shows a wide range of tips generally available from stock. For sizes not shown, refer to the diagrams anddescription key at the bottom of the page, and order what you need. All measurements will be accurate. However, over-alllength, in 1/8-in. multiples, will be held to within 1/16-in.Tapers, water holes, and nose designs are the same as the standard straight tips in this catalog.Water tubes can be furnished.Standard nose designs other than those shown here may be furnished on short order. Follow the “Key to Description”,using a ‘B’ for Dome nose, ‘C’ for flat nose, ‘E’ for truncated cone, and ‘F’ for radius nose.DOUBLE-BENT, ADDITIONAL NOSE DESIGNS‘A’ POINTED NOSE‘B’ DOME NOSECLASSKEY TO DESCRIPTIONTaperNo.FX-YZLD-OLengthOffset3 -16-TF Cold-Formed,Double-Bend TipsX Nose TypeABCDY RWMA Alloy Class1 Class 12 Class 2Z RW Taper Number4 4RW5 5RWL Length in inchesRefer to tablefor availabilityD Additional Lengthin 16thsO Offset in 16thsRefer to tablefor availabilityT With water tubes10‘C’ FLAT NOSE5RWFA Pointed 5-0160‘D’ OFFSET NOSECLASS 21FD Offset 0FD-1536-6FD-1536-20165-3570165-3580FA Pointed 0167-1600167-1620Visit www.tuffaloyproducts.com for updated product listingsFD Offset -3520FD-2536-20167-3580FD-2538-16167-3620
bent tips TUFFALOY‘A’ POINTED 6 FA-25212-16FA-1426-20 FA-2426-20FA-14214-20 FA-24214-20FA-15214-20 -2430-16FA-1428-16 FA-2428-16FA-2528-16FA-2436-20FA-1536-20 FA-2436-20FA-14212-8 FA-24212-8FA-15212-8 FA-25212-8FA-1538-8FA-2538-8‘D’ OFFSET NOSEFD-1524-20 FD-25212-8FD-1526-12 FD-2526-12FD-15212-16 FD-25212-16FD-1426-20 FD-2426-20FD-1428-16 FD-2428-16FD-1536-20 FD-2536-20FD-2538-16Special & Custom Parts available, contact us for a quotation (888) 654-935311
TUFFALOY bent tipsSINGLE-BEND TIPSFP-2532-10Part No.167-5540FP-2428-9.5Part No.167-4260FP-2523-7Part No.167-5060FP-2527-15Part No.167-5220FP-2423-7Part No.167-5055FP-2430-8Part No.167-5065FP-2530-8Part No.167-5070Cold-formed tips with a single bend have standardpointed-nose design. Other single-bend tips with flatnoses (below) or other special designed noses andconfigurations are available on special order. Theseare of Class 2 alloy; Class I alloy can also be ordered.SE-4268Part No. 170-4268SE-4269Part No. 170-4269MISCELLANEOUS TIPSDouble bend and flattened tips are made from bar stock.These are some of the standard designs available, but specialdesigns can also be made. These are of Class 2 alloy; Class Ialloy can also be ordered.SE-4270Part No. 170-4270SE-4273Part No. 170-427312SE-4274Part No. 170-4274SE-4275Part No. 170-4275SE-4271Part No. 170-4271SE-4276-1Part No. 170-4276-1Visit www.tuffaloyproducts.com for updated product listingsSE-4272Part No. 170-4272SE-4276Part No. 170-4276
miscellaneous tips TUFFALOYThese standard bent tips are in addition to those shown on page 11.They are of class 2 alloy; Other alloys can also be ordered.SE-4277Part No. 170-4277SE-4278Part No. 170-4278SE-4279Part No. 170-4279SE-4282Part No. 170-4282SE-4284 (short water hole)Part No. 170-4284SE-4287Part No. 170-4287SE-4280Part No. 170-4280SE-4281Part No. 170-4281SE-4283Part No. 170-4283SE-4285Part No. 170-4285SE-4286Part No. 170-4286SE-4288Part No. 170-4288Special & Custom Parts available, contact us for a quotation (888) 654-935313
TUFFALOY miscellaneous tipsSE-4089-4Part No. 170-4090SE-4535Part No. 186-0520SE-4089-5Part No. 170-40895RW: C-507-5Part No. 186-05074RW: C-507-4Part No. 186-0508These straight tips have weldingfaces angled scriptionN-15 thru h No.186-0015186-0016186-0027186-0028BACK UP ELECTRODESRECTANGULAR 25RW4RW4RW5RW11/211PartNo.ROUND FACE220225221 thru 224226 thru 2292121These tips are all machined from bar stock.Special designs can be made to order.*311, 313 and316 availablewith CopperTungsten face.See pg. 35301 thru 30414305 thru 3153164RW4RW5RW5RW7/87/87/87/8Additional Back Up Electrodes withCopper Tungsten Facings – See Page 35Visit www.tuffaloyproducts.com for updated product listings311 *312313 *315316 *PartNo.186-0311186-0312186-0313186-0315186-0316
swivel tips TUFFALOYSwivel tips have ball-jointedswivel heads to compensatefor minor misalignment, andto eliminate marking of thework surface. They are allmachined from Class 2 alloybar stock. The S-and SSSeries tip water hole doesnot reach the head. In theOS and OSH models, thewater does contact thehead, and O-rings are usedto seal it. In the SS Seriesa spring is used to keeppressure on head forbetter positioning.Class 1 and class 3heads are also available.Note: Standard swiveltilt is approximately18’, a 25’ swivel isavailable on request.Add suffix “HS” toabove part number.S-Series*(Tuffcap SS-353SS-354182-3353182-3354*Will fit Tuffcap adapter shanks having No. 5 RW tapers, as shown on page 8.TUFFALOY refractory metal-faced W5RWFacing 185-1260185-1270FlatDescriptionPartNo.The TUFFALOY copper-tungsten, tungsten and molybdenum-faced tipslisted here withstand greater heat and pressure, at the expense ofsome conductivity. Besides being used for spot welding high resistancebase metals, they are useful in achieving “heat balance” when weldingdissimilar metals. (The higher resistance electrode is used against thelower resistance, or thinner, member, to help contain the heat generated.)They have the same diameters and tapers as the standard straight tips inthis catalog. Bodies are of Class 2 alloy. Lengths other than those showncan be ordered.POINTED NOSE ‘A’DOME NOSE ‘B’FLAT NOSE ‘C’Special & Custom Parts available, contact us for a quotation (888) 654-935315
TUFFALOY threaded tips“A” POINTED NOSE THREADED ELECTRODERWMAAlloyClass No.Part NumberPartDescription
The bright shiny look of TUFFALOY tips is the result of a passivation process that eliminates excessive oxidation. It reflects the deep-down quality built into these tips and into all TUFFALOY products. Only RWMA Class 1 (TUFFALOY 88) and Class 2 (TUFFALOY 77) tips are listed here. Class 3 alloy (TUFFALOY 55) tips are also available. For
