Raytron Technical Review RESEARCH ARTICLE WP-06-06
Stainless Steel Clad Copper: Welding Electrode Applications
Published: March 2026 Version: 1.0
DOI: 10.1000/raytron.WP-06-06
1. Introduction
1.1 Inverted Structure
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MEDIA TODO| Configuration | Core | Cladding |
|---|---|---|
| CCSS | SS | Cu |
| SSCC | Cu | SS |
1.2 Why Inverted for Welding
| Requirement | Solution |
|---|---|
| High temperature | SS surface |
| Wear resistance | SS hardness |
| Thermal conductivity | Cu core |
| Electrical conductivity | Cu core |
2. Material Structure
2.1 Typical Configuration
| Component | Material | Function |
|---|---|---|
| Core | Copper | Heat sinking, conductivity |
| Cladding | SS 304/316 | Wear surface, strength |
2.2 Properties
| Property | SSCC |
|---|---|
| Surface hardness | 150-200 HV (SS) |
| Core conductivity | 100% IACS (Cu) |
| Thermal conductivity | High (Cu core) |
2.3 Advantage over Alternatives
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MEDIA TODO| Electrode Type | Wear Life | Conductivity |
|---|---|---|
| Cu-Cr-Zr | Moderate | High |
| W-Cu | High | Moderate |
| SSCC | High | High |
3. Welding Electrode Requirements
3.1 Resistance Welding
| Parameter | Requirement |
|---|---|
| Temperature | Up to 600°C at tip |
| Current | kA range |
| Force | kN range |
| Cycles | 10⁴-10⁶ welds |
3.2 Key Properties
| Property | Importance |
|---|---|
| Electrical conductivity | Current delivery |
| Thermal conductivity | Heat dissipation |
| Hardness | Wear resistance |
| Softening temperature | High-temperature stability |
3.3 Failure Modes
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MEDIA TODO| Mode | Cause |
|---|---|
| Mushrooming | Softening, deformation |
| Wear | Abrasion, erosion |
| Sticking | Material pickup |
4. SSCC Performance
4.1 Conductivity
| Region | SSCC |
|---|---|
| Core | 100% IACS |
| Overall | 80-90% IACS |
4.2 Hardness Retention
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MEDIA TODO| Temperature | Cu-Cr-Zr | SSCC |
|---|---|---|
| RT | 130 HV | 180 HV |
| 300°C | 100 HV | 170 HV |
| 500°C | 60 HV | 150 HV |
4.3 Wear Life
| Electrode | Welds to Redress |
|---|---|
| Cu-Cr-Zr | 500-2000 |
| W-Cu | 2000-10000 |
| SSCC | 2000-5000 |
4.4 Cost Comparison
| Electrode | Relative Cost | Life | Cost/Weld |
|---|---|---|---|
| Cu-Cr-Zr | 1.0 | Low | Moderate |
| W-Cu | 3.0 | High | Moderate |
| SSCC | 1.5 | Moderate-High | Low |
5. Applications
5.1 Spot Welding
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VIDEO TODO | Application | SSCC Benefit |
|---|---|
| Automotive | Longer life |
| Sheet metal | Good conductivity |
| Galvanized | Anti-sticking |
5.2 Projection Welding
| Application | SSCC Suitability |
|---|---|
| Nuts/bolts | Good |
| Fasteners | Good |
5.3 Seam Welding
| Requirement | SSCC Performance |
|---|---|
| Continuous operation | Good heat dissipation |
| Wear | SS surface resistant |
6. Conclusion
6.1 Summary
| Advantage | Value |
|---|---|
| Conductivity | High (Cu core) |
| Wear resistance | High (SS surface) |
| High-temp stability | Good |
| Cost | Moderate |
6.2 Positioning
SSCC offers a balance between:
- Cu alloys (high conductivity, lower wear)
- W-Cu (lower conductivity, higher wear)
7. References
- RWMA Bulletin 16. (2020). Resistance Welding Manual.
- AWS C1.1. (2019). Resistance Welding.