Mallory Resistance Welding Electrode Materials

Primary Materials:
Mallory 328 Cr-Zr-Cu	80	75	525
Mallory 100 Co-Be-Cu	90	45	500
Elkanite 20W3 Cu-W	97	30	1000
Secondary Materials:
Elkanite 20K3 Cu-Wc	105	20	1000
Elkanite 100M Mo	85	20	1000
Elkanite 100W W	119	30	1000
Elkanite 35S Ag-W	91	52	900
Mallory 73 Be-Cu	111-114	45	300
Mallory 150 Ni-Be-Cu	90	62	480
Mallory 400 Co/Ni-Be-Cu	110	20	300

* Hardness quoted is typical for 25mm dia. bar. Higher or lower hardness will occur on other sizes and cross-sections. All materials have hardnesses equal to or in excess of those required by BS4577.

+ Conductivity I.A.C.S. (International Annealed Copper Standard). On this scale annealed copper is 100%

MALLORY 328 Chromium-Zirconium-Copper alloy

Best all round alloy. Can be used on most parent metals and as an electrode material in the majority of resistance welding processes. Supersedes Mallory 3 – Chromium Copper alloy – as its greater temper resistance generally gives superior electrode life. Particularly recommended for spot and seam welding of coated steel.

Having greater strength and hardness, but a lower electrical conductivity than Mallory 328, this alloy is particularly recommended for spot welding and seam welding of stainless steel, projection and cross-wire welding dies, flash and butt welding dies for all materials, and as the backing material for Elkanite tips and facings. It is also used for current carrying, load bearing members of resistance welding machines such as gun arms, holders and patterns.

ELKANITE 20W3 Sintered Copper-Tungsten

A material made by powder metallurgy techniques combining the hardness and wear resistance characteristics of tungsten and the electrical properties of copper. While the material is hard and wear resistant, its electrical conductivity is poor, therefore the material should be used as a relatively thin facing on an efficiently water cooled copper-alloy backing. The material is recommended for use as an insert or facing when projection, cross-wire, flash or butt-welding.

ELKANITE 20K3 Sintered Copper-Tungsten Carbide

Not recommended as a material for welding electrodes, but for the related processes of “hot riveting” and “hot upsetting” where the tungsten carbide content makes the material particularly resistant to abrasive wear by red hot metal.

ELKANITE 100M Pure Molybdenum

Used for spot and cross-wire welding of high conductivity metals. Finds particular use as an electrode for resistance welding or brazing of braided or solid copper conductors to ferrous or non-ferrous terminal lugs or fittings.

ELKANITE 100W Pure Tungsten

Similar applications to Mallory 100M but due to its extreme hardness and low ductility requires grinding to shape. Also occasionally used in some electrical upsetting operations.

ELKANITE 35S Sintered Silver-Tungsten

Used as an insert when welding silver faced electrical contacts to prevent copper contamination and for the sliding contacts used in high frequency resistance welding of steel pipe where copper contamination of the weld is a problem. Has also proved to be an excellent electrode material in high speed automated projection welding.

An alloy with extreme hardness and strength, but with relatively low electrical conductivity and softening temperature. Used for mechanical load bearing components such as electrode holders and shafts of seam welding machines and as an insert material on long flash butt welding dies

A precipitation hardenable copper alloy, which in the heat-treated condition possesses high strength, coupled with excellent thermal and electrical conductivity. These properties make it an excellent material for cooling inserts for moulds, nozzles for hot-channel systems and die casting pistons.

MALLORY 400 Cobalt/Nickel-Beryllium-Copper alloy

This alloy, which conforms to BS4577 A/4/2 and RWMA Class 4, offers a high degree of strength and hardness. It is widely used for electrode holders as well as for deep drawing moulds, bushes for deep drilling rods and in precision measuring equipment.