Spot Welding Electrode

Sounds like you need to work on your process, possibly look into a different holder?

I would think it far outweighs your above mentioned ideas.

I'd have a talk with the electrode supplier. If he's charging you for 100% of the electrode when 80% is actually scrap, then he's a thief.

Or, as Tim says, get a new holder.

Maybe you could glue them together..

http://www.cotronics.com/vo/cotr/ea_electricalconductive.htm

The sintering would be expensive to set up...If you had many thousands of these electrodes, then maybe...
Tungsten melting point (3420 °C)

http://www.cmwinc.com/tungsten-copper.php

Yea but seriously now, although its an interesting link... Kind of like gluing two ladders together rather than using the proper one to start with isn't it?

What's wrong with that....? Anyway,,just thinking out loud...

Ok ya got me LOL

The way I see it is if you are manufacturing something there will always be consumable components that go with every machine used in the fabrication process.

If you cant afford the consumables you probably cant afford to be in business much longer either. Either you need to find a cheaper supplier, a better consumable, a better fabrication system, or figure out why you cant afford them all together IE where and who is draining all the money out of the profits.

"due to arcing"

I'd be looking at the pressure*, time and current settings

(* flex and skidding)

But this might be of interest

If we give you a fully explained solution to your spot welding electrode consumable cost mitigation exercise will you include us in the citations of "your" report and relinquish a portion of your performance bonus to us?

We face our copper electrodes with Elkonite using silver solder. That way you can resurface them, or if you decide to discard them, you are scrapping a low cost part. No need to fabricate electrodes from solid Elkonite.

am new to this area, pls explain me clearly..

The best brazing (silver soldering) alloy to use is AWS BAg-1 (Silvaloy45). It is composed of 45Ag-15Cu-16Zn-24Cd by weight. It melts at 1125F and flows at 1145F. It should be used with an appropriate flux and in a ventilated area because Zn fumes are toxic. We purchase it in foil form (.003" thick), but wire works fine also. Heating can be done with any kind of torch. After soldering, you can let the parts air cool, or quench them in water. Water quenching has the advantage that it will help remove the flux residue. The copper alloys and the Elckonite have different contraction coefficients, and may distort slighly upon cooling, If this is a problem in your application, you may have to machine the Elkonite after soldering.

Small correction; it is the Cd fumes that are toxic. There is a Cd free version of BAg-1, but we have not used it yet. Do the soldering in a ventilated area and it shouldn't be a concern.

Have your supplier make up your electrodes 80% copper/chrome and 20% Elkonite tip.

Or possibly make your own tips.

will try it..