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How Do Abnormalities in the Water-Cooling System Affect Weld Spots in Copper-to-Copper Lap Spot Welding with a Medium-Frequency Spot-Welder?
Oct 15,2026
Copper conducts heat quickly during copper-to-copper lap spot welding with a medium-frequency spot-welder, and electrode water cooling is the key to stable weld-spot quality. Faults such as insufficient water flow, blocked pipes, water leakage, and excessively high water temperature cause weld-spot heat drift and produce various defects.
I Changes in Weld Spots
1.The electrode softens due to heat, weld-spot indentations deepen and indentation area increases, the workpiece sinks and collapses, and severe cases directly burn through
2.The weld-spot surface oxidizes and blackens, pitting and pits appear, and welding spatter increases significantly
3.Electrode material sticking occurs, copper nodules and tear pits appear on the weld-spot surface, and the sheet wrinkles at the lap position
4.Uneven cooling of the two-side electrodes causes one-side weld spots to overburn and the other side to have insufficient formation
5.Heat is uncontrolled, and weld-spot strength fluctuates
6.After electrode end-face deformation, the contact area increases, easily producing hidden cold joints
7.Weld-spot contact resistance is unstable
8.Local overheating of the weld spot causes high temperature rise at the weld-spot position during product operation
II Common Triggers of Water-Cooling System Abnormalities
1.Scaling and blockage of the cooling water filter and internal electrode water channels.
2.Abnormal chiller operation, excessively high cooling water temperature.
3.Water leakage and seepage at water-circuit joints, insufficient circulating water volume.
4.Pipe bending and uneven water-circuit distribution, inconsistent cooling effect on the two-side electrodes.
III Impacts of Water-Cooling System Abnormalities
1.High-temperature electrode wear accelerates, dressing and replacement frequency increase, and consumable consumption rises.
2.Long-term high electrode temperature increases circuit resistance, and equipment output is unstable.
3.Water leakage causes component corrosion, and high temperature also accelerates aging of equipment insulation parts, increasing failure risk.
Wuxi Haifei Intelligent Equipment Co., Ltd. https://www.haifeiwelder.com/
Wuxi Haifei Intelligent Equipment Co., Ltd. has been focusing on the R&D and production of spot‑welding machines for 17 years. The company has obtained ISO9001 Quality Management System Certification, China Compulsory Certification (3C) and CE Certification. It is a National High‑tech Enterprise, a Specialized, Refined, Differential and Innovative Enterprise of Jiangsu Province, a Specialized, Refined, Differential and Innovative Enterprise of Wuxi, and a Gazelle Enterprise in the Southern Jiangsu National Self‑Dependent Innovation Demonstration Zone.
Should you be interested in our spot‑welding machines, please contact us: 400‑0510‑750.
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Wuxi HAIFEI Intelligent Equipment Co., Ltd.
Wuxi HAIFEI Welding Equipment Co., Ltd.
Add: 28 Shuiyun Road, Yuecheng, Jiangyin, Jiangsu Province, China. (Postal Code: 214404)
Mobile: +86 18915302352
Email: wushijie@jshaifei.com