A Novel Nano Structural Copper and Copper Chromium
Resistance Spot Welding Electrode Tips
Mohammed A. Gebril Luay B Hussain
Mechanical Eng. Dept. Mechanical School of
Faculty of Engineering Materials and Mineral
Garyounis University Resources Engineering
Benghazi, Libya USM-Pinang, Malaysia
Tel: 00218927292986
E-mail:magebril@yahoo.com
Abstract
Materials for spot welding electrodes should have
sufficiently high thermal and electrical conductivities,
and sufficiently low contact resistance, to prevent
burning of the work piece surface or alloying of the
electrode face with it. Furthermore, it should have
adequate strength to resist deformation at operating
pressures and temperatures. Hardness and annealing
temperature must also be considered. In this respect,
Equal Channel Angular Pressing (ECAP) technique
was implemented at room temperature to refine the
grains sizes of pure copper and copper-1%Chromium
alloy to a nano-scale for spot welding electrode tips
application. Scanning electron microscopy (SEM) was
used to study the progress of grain refining under the
influence of rotation and number of passes during
pressing. Resistivity tests showed that the conductivity
was affected by number of (ECAP) passes. Elongated
fibrous nano grains have enhanced electrical
conductivity and hardness. High conductivity is one of
the critical factors to successful resistance spot
welding (RSW) in robotic and automotive industries.
Shear test of spot welded 303 stainless steel strips
indicated that the nano structural Cu-1%Cr electrode
tips used showed a superior performance. Therefore,
the ECAP process is successively applied and high
hardness, conductivity and durability of the electrode
tips was achieved.
Keywords: ECAP, Resistance spot welding, Nano
materials, hardness, shear strength
1. Introduction.
Resistance welding is one of the oldest of the
electric welding processes in use by industry today.
The weld is made by a combination of heat, pressure,
and time. As the name resistance welding implies, it is
the resistance of the material to be welded to current
flow that causes a localized heating in the part. The
pressure exerted by the tongs and electrode tips,
through which the current flows, holds the parts to be
welded in intimate contact before, during, and after the
welding current time cycle. The required amount of
time current flows in the joint is determined by
material thickness and type, the amount of current
1
F.M. Shuaeib
Mechanical Eng. Dept.
Faculty of Engineering
Garyounis University
Benghazi, Libya
flowing, and the cross-sectional area of the welding tip
contact surfaces (See Figure 1). Materials for spot
welding electrodes should have sufficiently high
thermal and electrical conductivities, and sufficiently
low contact resistance, to prevent burning of the work
piece surface or alloying of the electrode face with it.
Furthermore, it should have adequate strength to resist
deformation at operating pressures and temperatures.
Because the part of electrode that contacts the work
piece becomes heated to high temperature during
welding, hardness and annealing temperature must also
be considered. Electrode materials have been classified
by Resistance Welder Manufacturers Association
RWMA into two composition groups: copper-based
alloys and refractory metal compositions. These
classifications cover a wide range of resistance
welding electrode materials to meet most applications
[1]. In addition to these standard materials, there are a
number of unclassified copper alloys and other
materials that may be suitable for resistance welding
electrodes. Suitability will depend upon the
application. Although most requirements are met by
materials comply with RWMA standards [2]. Copper is
used for electrodes because it has a low resistance and
high thermal conductivity compared to most metals.
Unfortunately, when the electrodes get too hot, heat
marks on the surface of work pieces can form. The
electrodes also become susceptible to mushrooming.
Electrode mushrooming reduces their usable lifetime.
An attempt to overcome this entire problem is to
strengthen copper alloy via nano structure can be
developed. An attractive and viable approach or
mechanism for improving the strength of copper is to
introduce a fine Cr structure into Cu matrix, resulting
in a dispersion-strengthened alloy. Copper matrices
containing fine dispersions are particularly attractive
for their excellent combinations of thermal and
electrical conductivities, strength retention at elevated
temperature and overall micro structural stability.
Normally, grains refinement in metals is achieved by
either static or dynamic recrystallization at a certain
elevated temperature. However, it is therefore
surprising to find that grain refinement can also be
achieved by plastic deformation at room temperature.
Recently, there have been many reports on the
microstructure and properties of ultrahigh- strained
metals [3-7].
 Figure (1)
The extremely high amount of deformation
can be introduced by several different ways, e.g
compressed-torsion [5], and equal channel angular
pressing (ECAP) also called equal channel angular
extrusion (ECAE) [8-10],cyclic-extrusion-compression
[11], and accumulative roll-banding process [12] In
this work, ECAP have been chosen as the process
route, since by this novel technique, a very large
amount of strain can be introduced into a work piece
without altering its size. The cross section of the
specimen remains about equal before and after a
processing step, thus it is possible to subject one
specimen several times to ECAP in order to reach
highest degrees of plastic deformation. Sever plastic
deformation methods should meet a number of
requirement. These are ultra fine grain, uniform and
free from any crack. .
Therefore, the aim of this work is to develop nano
fibrous structural copper chromium alloy, highly
conductive with low electrical resistance to be used in
automatic resistant spot welding application.
2. Materials and Methods.
For ECAP, the tool (as shown in Figure 2a and b)
consists of a die with two intersecting channels of
identical cross-section. A specimen of almost the same
cross-section is placed into one of the channels, and a
punch then extrudes it into the second channel. Under
these conditions, deformation is achieved by simple
shear. When deformed by ECAP, the sample retains
the same cross-sectional area so that it is able to repeat
the process several cycles. Therefore, very large plastic
strains could be accumulated in the sample.
As shown, the die of for ECAP consists of to
channels at an angle of =120. The angle, ,
defining the arc of two channels is 0. The ECAP was
conducted at room temperature (20C).
The material used in this work was commercially pure
copper (99.9% pure), and copper-1% chromium alloy
which were prepared via melting and sand casting. The
alloy was fully annealed to 850 C o and held for 60
minutes. Then the specimens were machined to rod
tips with dimensions of 10 mm in diameter and 40 mm
in length for ECAP.
2
a: Sketch of an ECAP tool and specimen
deformation
b: The fabricated 120 die channel
Figure (2)
The initial grain size of pure copper is about
200m. The two material groups were subjected to
plastic deformation using the equal channel angular
pressing (ECAP) method. During ECAP the direction
and number of the billet passes through the channel are
very important for microstructure refinement. The pure
copper and the copper-1% chromium alloy groups are
designated as A1 and C1 respectively. The two groups
were pressed through the die using a plunge and four
passes was terminated and the samples were rotated
about the longitudinal axis by 90 in the same direction
after each consecutive pressing. This rotation
procedure was designated as route Bc and it led most
expeditiously to a homogeneous equiaxed-grained
structure. This was also confirmed by others [13, 14,
15]. The sample of group A1 (pure copper) was cut and
cold mounted for polishing.
The samples of group C1 (copper-chromium)
were cut using diamond cutter at transverse and
longitudinal directions with respect to pressing
direction of plunger side and mounted for polishing.
After that the samples were prepared for SEM
investigation by polishing and cleaning processes.
Cleaning process was performed by using ultrasonic
cleaner, then cleaned samples were dried using air gun
and subsequently etched with copper enchant in
etching solution ( 5g FeCl3, 98ml ethanol 95%, 1ml
HCl) for a time of 5 to 20 second. Scanning electron
microscopy was conducted at the voltage of 100kV.
The grain size was measured for each sample directly
from the grains having well-defined grain boundary.
The hardness test is important in order to ensure the
improvement of the samples for resistance spot
welding electrode tip materials. Knoop micro hardness
testing with 100gm were performed at room
temperature, the results were observed under a
microscope and measured using established formulas
or conversion tables according to ASTM E384. The
value of hardness was taken as the average of 10
measurement made on the tips surface.
Resistivity test was carried out after cutting the
samples at transverse and longitudinal directions with
1 mm thickness using diamond cutter and surface
preparation. The samples were formed as cylindrical
and rectangular shape in longitudinal and transverse
direction respectively. The test was accomplished by
four point probe method. The samples were fabricated
into truncated shape before weld test was carried out
on the electrode. This work was done using the lathe
machine and coolant is used to avoid grain growth of
samples due to heat generating during machining.
Shear test specimens were made from
austenitic stainless steel strips having dimensions of
0.7mm thickness, 16mm width and 50mm length. The
plates were polished and surface cleaned by sand
blasting to avoid any prevention of the current flow.
The foot press type spot welding machine was used in
this work to joint stainless steel samples. Welding
parameters have been manipulated during the stainless
steel samples welding until getting the best weld
characteristics. The adopted welding conditions are
given in Table 1.
Table 1: welding conditions for the 0.7 mm strips of
the 304 austenitic stainless steel.
Parameter Setting
Welding current
(Ampere) 7500
Pressure(kg) 80
Frequency(Hz) 50
Weld cycle (cycle) 9-16
Input voltage(volt) 240
Water flow
rate(liter/min) 1 dislocations in an adjacent grain.
As part of the complete spot welding process
investigation, it is important to study the structure of
the spot welding nugget area. Both nugget and total
weld diameter that failed through the weld interface
were measured using Transfer Microscope. Two
different etchings were used to study nugget structure.
The first etchant was Vilellas solution which has the
composition of 5ml HCl (2M), 1g picric acid(2,4,6
trinitrophinol), 100 ml of ethanol (95%) and a few
drops of H2O2. The H2O2 is used to accelerate the
etching process. The second etchant was Nital which
has the composition of 1-5ml HNO3, 100ml ethanol
(95%). Finally, the optical microscope was used to
examine the samples.
3
3. Results and Discussion.
3.1. Effect of ECAP on the Microstructure
of the Weld Area.
Figure 3 (a) and (b) shows the microstructure of
pure Cu and Cu-1%Cr alloy before and after ECAP
respectively. Clearly the pure copper sample shows
definite equal axis grain, while Cu-1%Cr consisted of
copper matrix with eutectic structure, Figure 3b. It
was noted that the change of grains to elongated shape
after four and seven passes of ECAP was observed,
figure3c. It is interesting that the eutectic structure is
also elongated and disperses as stringers in between the
copper matrix. Figure 3d and e show the
microstructure of Cu-1%Cr after 4 and 7 passes
respectively in longitudinal direction. Evidently, the
nano structure was obtained after 4 passes. It was
believed that deformation of the grain in the direction
pressing lead to fibrous tiny grains. Further passes lead
to produce nano grains, figure 3e and d. However,
microstructure of Cu-1%Cr after 4 and 7 passes
respectively in transverse direction showed equaxis
and round eutectic gains, Fgure3 f and g.
3.2. Effect of ECAP on Hardness.
The Knoop microhardness measured on the
surface of tips. Figure 4, clearly indicates that the
hardness of pure copper after ECAP is higher than pure
copper before ECAP process. The hardness of copper-
chromium was also improved by ECAP process due to
formation of nano grains. It is believed that ECAP
processes enhanced the hardness due to refinement of
the grain that leaded to reduction in grain sizes within
the submicron or nano range with boundaries having
high angles of miss orientation. It is postulated that
these high angles of miss orientated grain boundaries
causes stresses concentration ahead of a slip plane in
one grain may became active sources of new
 Figure 3: microstructure of pure Cu (a) and Cu-1% Cr alloy (b) before and after ECAP(c) respectively, (d)
microstructure of Cu-1%Cr in longitudinal direction after 4 passes, (e) microstructure of Cu-1% Cr in longitudinal
direction after 7 passes, (f) microstructure of Cu-1% Cr in transverse direction after 4 passes in the eutectic region
and (g) microstructure of Cu-1%Cr in transverse direction after 7 passes in the copper matrix region.
Figure (3)

112
Average of hardness kg/mm2
110
250

108
200
Hardness (kg/mm2)

106

% IASC
150 104

102
100

100

50 98

96
0

Pure copper before Pure copper after Copper-chromium Copper-chromium 94

ECAP ECAP before ECAP after ECAP Pure copper Cu-1%Cr after ECAP
Samples Electrode

Figure 4: Knoop hardness results of Pure Cu and Figure 5: IACS% for pure Cu and Cu-1%Cr alloy
Cu-1%Cr after and before ECAP
3.4. Effect of ECAP on Joint Strength.
3.3. Effect of ECAP on Resistivity.
The shear strength test of spot welded 304
Electrical resistivity can be shown in the form of austenitic stainless steel strips using the developed tips
%IACS. The %IACS is the acronym for the percentage was performed to evaluate the welded joint efficiency.
of International Annealed Copper Standard. The Results of the test are presented in Figure 6. As shown,
%IACS for standard annealed copper at 20oC is high shear strength values are obtained of welded
100%IACS. The corresponding electrical resistivity of stainless steel plates using Cu-1%Cr electrode tips
pure Cu is 1.7241 x 10-8 m (0.017241mm2/m). The after ECAP processes (after 4 passes) as compared to
calculation of the conductivity of Cu-1%Cr sample can pure Cu before ECAP and pure Cu after ECAP (4
be evaluated using the following equation. passes) electrodes. This is also due to the hardness
improvement of the developed electrode tips. In
IACS % = RIACS / Rsample x100% (1) general the shear strength depends on both the tip
contact area and the tip conductivity. Large nugget area
Where RIACS is equal to 0.017241mm2/m and, Rsample with low heat diffusivity leads to low shear strength.
is resistivity of sample. As the size of the nugget area increases, with proper
Figure (5) shows the %IACS for standard annealed welding conditions, the shear failure load increases and
copper at 20oC is 100%IACS and IACS% of Cu-1%Cr fracture could take place at one of the strips around the
alloy after 4 passes. Four probe resistivity results periphery of the weld at the heat affected zone
analysis indicated that the conductivity of Cu 1%Cr circumference, leaving the weld nugget or slug (fuse
welded area ) attached to the other strip (pull-out
alloy in the ECAP direction is improved by 10%, due failure). Figures (7), shows the pull-out to failure shear
to ECAP processes which lead to formation of strength test of the strips. As shown, the failure had lift
longitudinal grains with high angles which act as the nugget or slug, as usually termed, attached to the
channels to help in carrying the charge carrier. other strip interface, which indicates that the diffusion
Conductivity enhancement of Cu-1%Cr alloy after due to the spot welding is excellent. Furthermore,
ECAP gives good indication to improve the resistance Figures (6), shows that the shear strength of welded
spot welding application beside the improvement of stainless steel plates with ECAP tips is higher than that
hardness. for welded plates without ECAP processed tips.

4
 6

Electrode tip diameter

5.8
5.6
5.4

(mm)
5.2
5
4.8
4.6
4.4
0 Weld 50 Weld 100 Weld
Weld number
Figure 6: Shear strength test of spot
welded 304 stainless steel strips. (c) Cu-1%Cr after ECAP
Figure 8: Electrode tip diameter variation
300 with respect to number of weld.
250
Shear strength ( MPa)

200 In general Cu-1%Cr tips after ECAP showed

150 smaller tip diameter deformation during spot welding
100
as compared with Cu-1%Cr produced tips before
50
ECAP, and pure copper tips. This is due to the
0
formation of nano grains that lead to higher hardness
Pure Cu before ECAP Pure Cu after ECAP Cu-1%Cr after ECAP for both pure copper and Cu-1% Cr tips after ECAP
Electrode tips
process. This would lead to longer life for the pure Cu
Figure 7: Shear strength of spot welded 304 and Cu-Cr electrode tips produced by ECAP than the
stainless steel strips electrode tips without ECAP. The electrode
deformation occurred after each weld was investigated.
3.5. Electrode Deformation. The trend of tip diameter deformation after ECAP was
less than that of tip deformation produced before
The average diameter of electrode tips are ECAP. Therefore, the change of tip diameter for tips
illustrated in Figure 8 (a, b and c) which shows the produced before ECAP, was higher than after ECAP
changes in electrode tips diameter after 0, 50 and 100 process tips due to lower hardness.
weld number respectively for pure Cu before ECAP,
Cu-1%Cr before ECAP and Cu-1% Cr after ECAP (4 3.6. Welding Characterization Based on
passes). the Microstructure of Welded Zone.
Electrode diameter ( mm)

8 Figure (9) shows the complete feature of

6
RSW for the stainless steel welds using Cu-1%Cr
electrode tips. Nugget structure is well formed and a
4 thin area of heat-affected zone (HAZ) is observed
2 around the nugget area. Indention of the outer surface
of the strips was observed. This confirmed that the
0
0 Weld 50 Weld 100 Weld penetration or the depth of fusion extension into the
Weld number outer workpiece is in the accepted range (20 to 80%) of
the workpiece thickness. Increasing the nugget
(a) Pure Cu before ECAP
diameter will increase the breaking load of the welded
Electrode diameter ( mm)

8
joint. This explains why the strength of stainless steel
7
6 welds using Cu-1%Cr electrode tips after ECAP is
5 stronger than the others (refer to Figure 6). Figure (10)
4
3
shows SEM image of the weld flow direction which
2 started at the center of weld spot and progressed
1 toward the HAZ area. This progression by means of
0
0 Weld 50 Weld 100 Weld
the fusion area was in a fine columnar form while the
Weld number inner part is as equa-axis fine grains along the two
sheets interface.
(b) Cu-1%Cr before ECAP

5

Figure 9: SEM image Figure 10: SEM image of
Cu-1%Cr electrode tips weld flow direction
(25x) features (100x).
Figure 11(a), shows SEM image of stainless steel
welds using Cu-1%Cr tips. The image shows the
defined structure of nugget formation only. Figure 11
(b) shows that there is a thin HAZ observed, and
columnar grains can be seen from this image indicating
less heat was pronounced. Figure 12, shows the nugget
structure and the grains boundaries interface of
stainless steel specimens.
(a) (b)
Figure 11: SEM images shows (a) Thin HAZ using
Cu-1%Cr tips (130x) and (b) small HAZ using pure
Cu tips (600x).
(a) (b)
Figure 12: SEM images of stainless steel welded
using (a) Cu-1%Cr and (b) Pure Cu tips (500x).
4. Conclusions.
From this study the following points can be concluded:
ECAP produces nano elongated grain
boundary with fine sub-grain for both Cu and
Cu-1% Cr ranging from 100 500 nano-m for
four pass and less than 100 to 300 nano-m for
seven pass respectively.
The hardness of Cu-1%Cr was improved by
ECAP process compared to pure Cu and Cu-
1%Cr before ECAP process due to formation
of ultra fine and nano grains.
After ECAP process, the IACS % of Cu-1%
Cr increased due to formation of longitudinal
grains with high angles which act as channel
to helpe in carrying the charge carrier.
The shear strength of spot welded 304
stainless steel produced by Cu-1% Cr
electrode tips after ECAP process was higher
than that of tips produced without ECAP
process.
Cu-1%Cr Electrode tips after ECAP process
showed less deformation in comparison with
Cu and Cu-1% Cr tips before ECAP process.
The complete features of RSW nugget for 304
stainless steel welds using Cu-1%Cr electrode
tips after ECAP showed columnar grains, and
very thin area of heat affected zone (HAZ)
and nugget formed with less defects for the
joint of stainless steel using the improved
electrode tips.
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