Every spot under control: SVS standards for electrode caps
Electrode caps are designed for long service life and low wear in series production. Manufactured from cold-extruded raw material of consistent quality, the electrical resistance remains constant across all batches. The materials combine high conductivity with heat and wear resistance. All geometries are produced within tight tolerances and enable repeatable current and force application. Dressing surfaces are designed for burr-free post-processing and maintain the contact surface across multiple dressing passes.
Available in standard versions according to DIN ISO 5821 as well as customized versions based on drawings or samples. Geometry, material, and interface are precisely matched to your production environment.
Catalog
DIN ISO 5821 Catalog
Exemplary Materials
Zirconium-copper (CuZr), WIRBALIT® CA (CuAl2O3), WIRBALIT® HF (CuCr1Zr)
| Technical drawing | Form | d1 | d2 | d3 | l1 | l2+-0.5/-0 | e | R1 | R2 | Action |
|---|---|---|---|---|---|---|---|---|---|---|
 | Type A0 | 13 | - | 10 | 18 | 8 | - | 32 | - | |
 | Type A0 | 16 | - | 12 | 20 | 9,5 | - | 40 | - | |
 | Type A0 | 20 | - | 15 | 22 | 11,5 | - | 50 | - | |
 | Type B0 | 13 | 5 | 10 | 18 | 8 | - | 32 | - | |
 | Type B0 | 16 | 6 | 12 | 20 | 9,5 | - | 40 | - | |
 | Type B0 | 20 | 8 | 15 | 22 | 11,5 | - | 50 | - | |
 | Type C0 | 13 | - | 10 | 18 | 8 | - | - | - | |
 | Type C0 | 16 | - | 12 | 20 | 9,5 | - | - | - | |
| Type C0 | 20 | 15 | 22 | 11,5 | - | - | - | ||
 | Type D0 | 13 | 5 | 10 | 18 | 8 | 3 | 32 | - | |
 | Type D0 | 16 | 6 | 12 | 20 | 9,5 | 4 | 40 | - | |
 | Type D0 | 20 | 8 | 15 | 22 | 11,5 | 5 | 50 | - | |
 | Type E0 | 13 | - | 10 | 18 | 8 | - | - | 5 | |
 | Type E0 | 16 | - | 12 | 20 | 9,5 | - | - | 6 | |
 | Type E0 | 20 | - | 15 | 22 | 11,5 | - | - | 8 | |
 | Type F0 | 13 | - | 10 | 18 | 8 | - | - | - | |
 | Type F0 | 16 | - | 12 | 20 | 9,5 | - | - | - | |
 | Type F0 | 20 | - | 15 | 22 | 11,5 | - | - | - | |
 | Type G0 | 13 | 5 | 10 | 18 | 8 | - | 32 | 5 | |
 | Type G0 | 16 | 6 | 12 | 20 | 9,5 | - | 40 | 6 | |
 | Type G0 | 20 | 8 | 15 | 22 | 11,5 | - | 50 | 8 |
Upload your technical drawing – we develop the perfect solution for your production line.
What lies behind consistent manufacturing quality
All components are manufactured in Germany and can be precisely tailored to your application. Standard versions are immediately available, ensuring short delivery times.
Manufactured with tight tolerances on high-performance machines with stable clamping systems and consistent tool settings to prevent dimensional deviations across series.
Consistently machined contact surfaces with low roughness reduce contact resistance and promote even current distribution across the weld zone.
All electrodes undergo quality-assured testing. For demanding use cases, we offer individual testing according to defined specifications.
We offer bespoke designs based on your technical specifications. Geometry and material are co-developed with your team to meet your production requirements.
Decades of experience shape every SVS product and contribute to the development of technical standards as an active member of the German Welding Association (DSV).
SVS Performance Features
For over 60 years, we have been a reliable partner in welding technology for manufacturers worldwide.
Applications
The function of electrode cap in spot welding
In resistance spot welding, two electrodes press the metal parts together with a defined force. This creates a stable contact with low contact resistance.
The electrode cap is located at the tip of the electrode. It establishes direct contact with the workpiece, transfers current and force to the joining zone, and concentrates the energy input onto the weld spot. A short, strong current pulse flows specifically through the contact area. The electrical resistance generates heat, which melts the material surfaces locally and bonds them together.
Replacement is quick in the event of wear, as only the cap is replaced, not the entire electrode.
Quality-relevant features of electrode caps
The material used must conduct the welding current into the joining zone with low resistance. Fluctuations can directly impact weld quality and process stability.
If the hardness is too low, the contact surface deforms under welding pressure. This affects the current flow and weld shape and can significantly shorten the service life of the cap.
Only tight tolerances allow for a defined contact surface. Deviations lead to uneven force application, fluctuating current density, and unstable weld conditions.
Different microstructures or unevenly distributed alloying elements lead to uneven burn-off and scattered energy input. A homogeneous material structure is crucial.
The dressing surface must allow for controlled material removal. Only then can the contact geometry be reliably maintained after reconditioning.
Manufacturing process
Manufacturing process of electrode caps
Precision and consistency are key to producing high‑quality electrode caps. Our manufacturing process ensures reliable performance, long service life, and consistent quality. It is based on selected materials and a comprehensive testing concept that includes dimensional and visual inspections at every stage. This guarantees adherence to tight tolerances and meets the highest standards of industrial series production.
- 1Step 1
Material control
We use high-quality materials with consistent properties to ensure stable conductivity and mechanical strength across all batches.
- 2Step 2
Multi‑stage cold forming
Caps are pressed in several forming stages using SVS in‑house tools to achieve precise geometries and structural integrity.
- 3Step 3
Cleaning
Multiple cleaning steps remove contaminants to ensure clean contact surfaces and stable weld joints.
- 4Step 4
Shipping preparation
Caps are packaged dust-free and securely for transport, ensuring immediate readiness and protection from damage.
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