Every Spot Under Control:
SVS Standards for Electrode Caps
Electrode caps are built for long service life and low wear in high-volume welding. They are manufactured from cold-formed copper of consistent quality, ensuring stable electrical resistance across all batches. The copper alloys used combine high conductivity with thermal and wear resistance.
All geometries are produced within tight tolerances, enabling precise and repeatable transfer of current and force. Machined surfaces are deburred and retain their function over multiple dressing cycles.
Available as standard versions according to DIN ISO 5821 or as custom parts based on drawings or samples. Geometry, interface and material are precisely matched to your requirements.
Catalog
Exemplary Materials
WIRBALIT® CA (CuAl2O3), WIRBALIT® HF (CuCr1Zr) and Zirconium-copper (CuZr)
| 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 |
Drawing parts required? Simply upload your file and get a quote.
We ensure the quality of your welding processes.
We process highly conductive copper components with a defined and verified purity level. All current-carrying surfaces are precisely machined and optimized for minimal contact resistance.
All components are manufactured in Germany and precisely matched to your application. Standard designs are available from stock, ensuring short delivery times and maximum flexibility.
Tight tolerances, stable production equipment, and consistent clamping conditions ensure reliable dimensional accuracy and repeatable results across all production runs.
Our products are subject to strict quality inspections. For special requirements, individual tests are carried out according to defined specifications.
Flexibility is our strength. Our products are available in numerous variants and can be manufactured with high precision to fit your system requirements.
For decades, we have contributed our expertise to SVS products and, as an active member of the German Welding Society (DVS), have helped shape technical standards.
SVS Capabilities
For over 60 years, we have been a reliable partner for manufacturers worldwide in welding technology.
Fundamentals
Function of Electrode Caps in Spot Welding
In resistance spot welding, two electrodes press the metal parts together with defined force. This creates a stable contact with low electrical resistance.
At the tip of the electrode sits the electrode cap. It provides direct contact with the workpiece, transmits current and force into the joint and focuses the energy on the weld spot. A brief, high-intensity current pulse flows through the contact area, generating resistance heat that melts the surfaces locally and bonds them metallurgically. When worn, the cap can be replaced quickly without changing the entire electrode.
Parameters of Electrode Caps
Hardness determines how well an electrode cap resists wear during high-volume welding. Harder materials better resist mechanical abrasion and deformation from repeated weld cycles. However, hardness must be balanced to retain sufficient thermal conductivity to ensure consistent process performance.
Tight tolerances in geometry and contact surfaces ensure repeatable positioning and stable transmission of current and force. Even minor deviations can cause inconsistent nugget formation or contact stability.
Materials must combine high conductivity with thermal and mechanical durability. Alloys such as CuCrZr or CuCoBe provide consistent energy input and long service life. A homogeneous microstructure is essential for stable performance over time.
To maintain functional surfaces, the cap must allow precise and burr-free redressing. This secures reliable contact and extends service life. Good machinability also supports efficient production and fast on-site maintenance.
Manufacturing Steps
Manufacturing Process of Electrode Caps
High-quality electrode caps require precision at every stage. SVS combines selected materials with a comprehensive inspection system for both dimensions and surface quality. This ensures tight tolerances, long service life and reliable performance tailored to the demands of industrial series production.
- 1Step 1
Material Inspection
The process starts with selecting high-quality materials with consistent properties. This ensures stable conductivity and mechanical strength across all batches.
- 2Step 2
Multi-Stage Cold Forming
The caps are pressed through several forming stages using SVS tooling and high pressure. This ensures precise geometries and structural integrity.
- 3Step 3
Cleaning
A multi-step cleaning process removes all residues and ensures ideal surface conditions for repeatable weld quality.
- 4Step 4
Packaging for Shipment
Caps are packaged in dust-protected, impact-resistant units. This prevents transport damage and allows immediate use in production.
