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A successful resistance spot welding process generally requires a welding power supply, a spot welding head, and a weld monitor or weld checker. Selecting the right accessories for these critical components can enhance and improve your results, and provide additional safety for your operators.

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Available models

Rating
THP
PHP
HFP
GHP
HDHP
DC (watt seconds)
125
125
500
125
500
AC (KVA-1/2 cycle)
2
2
7.5
2
10
Force range (Min - Max)
1 lbs - 7 lbs
1 lbs - 7 lbs
3 lbs - 25 lbs
N/A
N/A
Cable size (AWG)
#2 or #6
#2 or #6
#2
#2 or #6
#2
Cable length
4 ft or 10 ft
4 ft or 10 ft
5 ft or 10 ft
4 ft or 10 ft
7 ft
Electrode series
ET0400
EP0400 or EP0400
EP0800 and EP0800
EP0800
EP0900

GHP Handpiece

The Model GHP handpiece is trigger fired and used to weld or tack materials that don’t require stringent force control.

Handpieces are available with either 4-foot or 10-foot long cables. As a general rule, the energy delivered to the workpiece with 10- foot #6 cables will be approximately 15% of that delivered with 4-foot #6 cables. Handpieces are furnished with cables, as indicated in the following table, and one pair of RWMA electrodes.

 

HDHP Heavy Duty Handpiece

The Model HDHP handpiece is switch fired and used to weld or tack materials that don’t require stringent force control.

Handpiece comes with 7-foot long cables. Handpieces are furnished with cables, as indicated in the following table, and one pair of RWMA electrodes.

 

HFP High Force Handpiece

The HFP Handpiece comes with 5-foot long cables. Handpieces are furnished with cables, as indicated in the following table, and one pair of RWMA electrodes.

 

PHP Probe Handpiece

The Model PHP handpiece is used to weld small parts which require less than 125 watt-seconds or 1/2 cycle AC, and welding forces less than 7 pounds.

Handpieces are available with either 4-foot or 10-foot long cables. As a general rule, the energy delivered to the workpiece with 10- foot #6 cables will be approximately 15% of that delivered with 4-foot #6 cables. Handpieces are furnished with cables, as indicated in the following table, and one pair of RWMA electrodes.

 

THP Tweezer Handpiece

The Model THP tweezer weld handpiece is used to weld small parts which require less than 125 watt-seconds or 1/2 cycle AC, and welding forces less than 7 pounds.

Tweezer weld handpieces are available with either 4-foot or 10-foot long cables. As a general rule, the energy delivered to the workpiece with 10- foot #6 cables will be approximately 15% of that delivered with 4-foot #6 cables. Tweezer weld handpieces are furnished with cables, as indicated in the following table, and one pair of RWMA electrodes.

 

VBTWK/115 – Ball Tacking Kit

This ball tacking kit is designed for aerospace and general industry applications where precise placement of stainless steel, Inconel, and other metal balls is desired.

Typically used with GHP or HFP handpiece and a CD-A125A or CD-A300A CD welding power supply.

 

The Model SMZ-660 Stereo Zoom Optic Pod (1) is supplied with 10X Eyepieces and a 0.5X Objective Lens. It provides magnification which is adjustable from 4.0-25X and a working distance of 211 mm. Its lightweight housing is airtight, anti-mold and anti-electrostatic. It includes the C-Bonder Arm and is compatible with any Model 50 or 80 Series welding head.


The Model OMA optic mounting assembly (2) provides the posts and hardware required to support the optic pod. The Model BPTL, Thin-Line base plate (3) is drilled to accept all 80 Series Thin-Line weld heads and the optic mounting assembly. The base plate is 6 inches wide x 14-7/8 in deep x 1/4 in (15.2 cm x 37.8 cm x 6.3 mm). The BLFOI fiber optic illuminator system (4) transmits light through bifurcated, fiber optic light guides to produce cool, flicker-free, high-intensity light at the worksite. The Model BLFOI operates at 115 volts, 50/60 Hz. Specify Model BLFOI/230 for operation at 230 volts, 50/60Hz.

The Model TMMWC (Trinocular Mounted Microscope with
Camera) Stereo Zoom Microscope is supplied with 10X Eyepieces and a 0.5X
Objective Lens. It provides magnification which is adjustable from 4.0-25X
and a working distance of 211 mm. It is available with Mounting Kits for weld heads shown in table below or sold as standalone system using part number 270-607 noted below. It is compatible with most 70 & 80 Series welding heads.

The Model IVSC (Inspection Vision System w/Camera) is a standalone system and
contains a Macro video lens on extended post stand with HD Measurement camera
and diffused LED ring light. Includes 23 in LCD monitor and Flash Card for saving images.

In many cases, the process is smaller than what the human eye can see, thus magnification is key to properly observing the process results. We offer a range of different magnification devices that can be used to look at the weld to detect small
defects. An eye loupe is an indispensable item that can be used for quick observation. To take pictures of the process, portable, USB microscope, desktop stereoscopes, and Trinocular Microscopes are available.

An eye loupe is an indispensable item for quick observation. This pocket sized tool will magnify the process 10x and allows for the first line of inspection.

Kit number
Description
Applicable weld heads
10-430-01
SMZ-660 Stereo Microscope kit, includes OMA, BPTL and BFLOI, 120 V
80F,80A/EZ,86,87A/EZ
10-430-02
SMZ-660 Stereo Microscope kit, includes OMA, BPTL and BFLOI, 230 V
80F,80A/EZ,86,87A/EZ
10-431-01
SMZ-660 Stereo Microscope kit, includes OMA, and BFLOI, 120 V
71 weld head
10-431-02
SMZ-660 Stereo Microscope kit, includes OMA, and BFLOI, 230 V
71 weld head
10-432-01
SMZ-660 Stereo Microscope kit, includes OMA2, and BFLOI, 120 V
72/180 weld heads
10-432-02
SMZ-660 Stereo Microscope kit, includes OMA2, and BFLOI, 230 V
72/180 weld heads
10-440-01*
IVSC, Inspection Station, includes Macro lens, Stand, Ring light, Smart Camera w/measurement tool, 23 in LCD monitor
N/A
10-450-01*
TMMWC-120, Trinocular Micro Scope Kit, includes 1080P HD Camera, 23 in LCD Monitor, OMA, BPTL and BFLOI, 120 V
80F,80A/EZ,86,87A/EZ
10-450-02*
TMMWC-230, Trinocular Micro Scope Kit, includes 1080P HD Camera, 23 in LCD Monitor, OMA, BPTL and BFLOI, 230 V
80F,80A/EZ,86,87A/EZ
10-451-01*
TMMWC-120, Trinocular Micro Scope Kit, includes 1080P HD Camera, 23 in LCD Monitor, OMA2, BPTL and BFLOI, 120 V
72/180 Weld Heads
10-451-02*
TMMWC-120, Trinocular Micro Scope Kit, includes 1080P HD Camera, 23 in LCD Monitor, OMA2, BPTL and BFLOI, 230 V
72/180 Weld Heads
270-607*
Trinocular Microscope System, includes Trinocualr Stereo Microscope, 0.4x video coupler, 10x eyepieces and 0.5x Objective lens, Focus Mount, 1080P HD camera, 23 in LCD monitor
50 series weld heads, and any weld head with existing Microscope mount. Requires BFLOI light source
475-549
Jeweler’s Loupe
N/A
8-453-01
USB Microscope and Stand
N/A

*includes image capture software

Part name
Part number
Process
Fume Extractor-Small
4-61359-01
Spot welding
Fume Extractor-Large
720-225
Fusing, Brazing

Spot welding, fusing and brazing are all processes that can eject material of various sizes from the part. Fume extractors are necessary to remove harmful airborne particles so that operators and engineers are not exposed. These sometimes toxic fumes need to be collected and properly filtered. Use the table above to identify the best fume extractor for a given process.

Model
Part number
kVA
GPM (STD)
OTC-1.0A Chiller
4-66736-02
<100
4
OTC-2.0A Chiller
4-66736-05
<200
7
OTC-5.0A Chiller
4-66736-07
<500
12
OTC-7.5A Chiller
4-66736-09
<500
18
Water connector kit, small
4-69984-01
Water connector kit, large
4-66985-01

Water chillers are necessary for cooling higher powered welders. They control the temperature of the water to keep condensation from building when facility water cannot. The following chillers provide the necessary cooling capacity for the approximate kVA Rating running at full power and duty cycle. The table below is a general rule, always consider each circuit in the welding system for required GPM (Gallons Per Minute).

Cold Air Guns use vortex tube technology and filtered compressed air to produce sub-freezing air as low as -30 deg F for numerous industrial spot cooling applications. With no moving parts to wear out, Cold Air Guns require no electricity, just a compressed air source. The Vortex Cold Air Gun System includes a magnetic base and a 5 micron auto-drain compressed air filter. Great for spot cooling when water cooling is not sufficient or available.

  • Compressed air pressure: (psig) 80 – 100
  • Inlet size: (NPT pipe thread, inches) ¼
  • Minimum outlet temperature, deg F: (at 70 deg F inlet air) -10
  • Air consumption @ 100 psig: (scfm) 15
  • Outlet air flow rate: (scfm) 2 to 15
  • Dimensions, inches – overall length: 19 5/8,
  • Diameter: 1 ¾, nozzle length: 9

One method to test the strength of a weld is to pull the two joined materials
apart. The 200 lb pull tester can be configured for tension or compression testing applications up to 200 lbF (890 N) for laboratory and production needs. The 10-420-01, 200 lbs pull tester comes with motorized test stand, force gauge, and wedge grips. Platform is customizable for specific applications.

Auto drain air filter, 5 micron element, metal bowl with sight glass, differential pressure indicator, for use with all air actuated weld heads.

The Model FS2L two-level footswitch is intended for use with all AMADA power supplies. The first level actuates the weld head via the air valve driver of the power supply; the second level, along with the force firing switch in the weld head, initiates the welding current.


The Model FS1L one-level footswitch also may be used with all AMADA power supplies. The single level switch actuates the weld head and initiates the welding current simultaneously (when the firing switch closes).

Single level Firing Switch without safety guard. Used to fire power supplies immediately upon initiation.

The Model CP cable pedal pivots under the heel for optimum force control. It is equipped with an adjustable down-stop which prevents the application of excess force. It is rated at 25 pounds, and can be used with the 50F, 80F, 86F, or 87F Thin-Line™ weld heads.

 

The Model MSP medium force swing pedal is fully adjustable for length, stroke, angle and left or right-foot operation. It provides a 5-to-1 mechanical advantage and is rated at 100 pounds. It is used with 83F, 84F, 88F, 89F, and 180F Thin-Line weld heads.

Holds Heidenhain type displacement sensors ST-1278 and ST-3078 to Thinline series weld heads as noted.

Highly conductive workpiece materials generally require electrodes of high resistance. Similarly, hard materials require softer, copper-based electrodes. When welding dissimilar materials such as copper and nickel, the normal choice would be a molybdenum electrode against the copper and a GLIDCOP electrode against the nickel.

 

If stored energy or half-cycle equipment is used to weld dissimilar materials, place the more resistive material against the negative electrode. Likewise, if similar materials with thickness ratios greater than 4:1 are welded, place the thinner material against the negative electrode.

 

To clean electrode surface and maintain shape, electrodes should be dressed with either 600 or 1000 grit silicon carbide paper, rather than with a file. Refer to page 7 for polishing disks.

Model
Capacity
Scale
Notes
FG20*
20 lbs
20 lbs x .2 lb
Serialized
FG100*
100 lbs
100 lbs x 1 lb
Serialized
FG200*
200 lbs
200 lbs x 2 lb
Serialized
FG10kg*
10 kg
10 kg x 0.1 kg
Serialized
FG100kg*
100 kg
100 kg x 1 kg
Serialized

*Calibration Certificate models also available

 

Electrode force gauges are used to establish weld schedules and to calibrate weld heads and handpieces. They are color coded to indicate the usable force range. The accuracy is ±2% of full scale.

GLIDCOP - Dispersion strengthened Copper with 0.15% Aluminum Oxide - 68B Rockwell hardness, 92% conductivity. Longer life, greater thermal stability, higher strength than RWMA 2. Generally interchangeable with RWMA 2 without changing schedules. All AMADA weld heads are supplied with GLIDCOP electrodes.

 

RWMA 2 - Copper Chromium alloy - 83B Rockwell hardness, 85% conductivity. Used for welding steels, nickel alloys and other high resistance materials.

 

RWMA 3 - Copper Cobalt Beryllium alloy - 100B Rockwell hardness, 48% conductivity. Used for welding high resistance materials requiring high weld forces.

 

RWMA 11 - Copper Tungsten alloy 99B Rockwell hardness, 46% conductivity. Usually inserted into an RWMA 2 shank. Used for welding cuprous and precious metals. Used for light projection welding dies.

 

RWMA 13 - Tungsten - 70A Rockwell hardness, 32% conductivity. Usually inserted into an RWMA 2 shank. Cannot be machined but may be ground to the desired shape. Used to weld non-ferrous metals such as copper and brass.

 

RWMA 14 - Molybdenum - 90B Rockwell hardness, 31% conductivity. Usually inserted into an RWMA 2 shank. Machineable. Used for welding copper, silver, gold and their alloys.

Model
Material
Face length
Face width
Face depth
Face length
EU1000
RWMA2
1.125 in
.020
.030
.080
EU1002
RWMA2
2 in
.020
.030
.080
EU2030M
Copper Clad Moly
1.125 in
.020
.030
.080
EU2030ML
Moly
2 in
.020
.030
.080
EU2537M
Moly
1.125 in
.025
.037
.100
EU2030MR
Moly
1.125 in
.020
.030
.080

Unibond electrodes are used for parallel gap bonding and reflow soldering. Generally, RWMA2 copper Unibond electrodes are used with resistive and/or hard materials such as gold plated kovar and nickel. Molybdenum Unibond electrodes are used for bonding conductive or soft materials such as copper or gold. The face of a Unibond electrode is 0.020 in (0.5 mm) wide by 0.030 in (0.75 mm) deep. In unfixtured applications, this limits their use to bonding ribbons (wire) which are at least 0.010 in (0.25 mm) wide because of the limited visibility.

Model
Face width (in)
Face depth (in)
Face gap (in)
Face length (in)
Max force (oz.)
Max force (kgf.)
UTM111L
.009
.010
.001
.025
33
.94
UTM112L
.010
.010
.002
.025
33
.94
UTM152L
.010
.005
.002
.025
17
.47
UTM222L
.018
.020
.002
.050
132
3.75
UTM237L
030
.020
.007
.050
161
4.57
UTM111C
.009
.010
.001
.025
33
.94
UTM112C
.010
.010
.002
.025
33
.94
UTM222C
.018
.020
.002
.050
132
3.75
UTM224C
.020
.020
.004
.050
132
3.75
UTM224L
.020
.020
.004
.050
132
3.75
UTM112CS
.010
.010
.002
.015
33
.94
UTM112LS
.010
.010
.002
.015
33
.94

Unitips are electrodes for parallel gap bonding of gold plated kovar, copper, or gold ribbons (wires) which are smaller than 0.010 in (0.25 mm). They are made from two pieces of molybdenum, which are permanently bonded to an insulating spacer. This fixed gap and bonded construction results in a tip which wears uniformly when properly dressed. The length of the Unitip and the flat area on the front allows it to bond ribbons extremely close to the walls of packages as deep as 0.450 in (11.5 mm). The narrower Thinline “L” series Unitips have a tapered profile, enabling them to be used closer to the corners of packages.

Model PD Polishing Disks, 600 and 1000 grit silicon carbide, 1.5 in diameter. Package of 50. 10-031-02, PD-600 10-031-02-01, PD-1000

 

Model CPD Ceramic Polishing Disks, 1 in square x .025 in thick. Package of 20.

Model
Size
KR207
.002 in x .0065 in x 10 ft
KR306
.002 in x .010 in x 20 ft
KR307
.002 in x .005 in x 20 ft
KR310
.003 in x .010 in x 20 ft
KR315
.003 in x .015 in x 20 ft
KR320
Part number
Part name
Description
145-025
145-025, Nickel Battery Tab
.250 in x 1.125 in x .005 in
Nickel 201
145-026
145-026, Nickel Battery Tab
.375 in x 1.125 in x .005 in
Nickel 201

Other sizes available upon request

Kit
10-415-01
10-416-01
10-417-01
10-418-01
Includes
Includes 20 lbs force gauge, 1000 grit polishing disc, 10X loupe, safety glasses and various electrodes
Includes 20 lbs force gauge, 1000 grit polishing disc, 10X loupe, safety glasses and various electrodes
Includes 100 lbs force gauge, 600 grit polishing disc, 10X loupe, safety glasses and various electrodes
Includes 100 lbs force gauge, 600 grit polishing disc, 10X loupe, safety glasses and various electrodes
Weld head model
80/71 Series
88 Series
180/73 Series
188 Series

Starting new welding project can seem daunting at first. Not only do you need to purchase the welding equipment, but also need to consider peripheral equipment to ensure that the process is successful and safe. We have created start-up kits for the different products to help you get started.

Part number
Part name
Description
10-377-02
UB/DC25 Calibration Kit
Calibration kit for UB/DC25, includes shunt, cables and necessary hardware
10-377-03
UB/DC25 Calibration Kit with Oscilloscope
Calibration kit for UB/DC25, includes oscilloscope, shunt, cables and necessary hardware
10-410-01
HF25/27 Calibration Kit
Calibration kit for HF25/27, includes shunt, cables and necessary hardware
10-410-02
HF25/27 Calibration Kit with Oscilloscope
Calibration kit for HF25/27, includes oscilloscope, shunt, cables and necessary hardware

Calibration of your equipment is essential to maintain proper operation, calibration should be done on an annual basis. These kits include everything needed to calibrate the UB/DC25 or HF25/27 power supplies. Choose the kit with or without oscilloscope depending on your needs.

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  • Automotive
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  • Medical
  • Semiconductor, Solar & Electronics
AMADA GroupThe AMADA Group is a world leader in the manufacture of machines for sheet metal processing. Established in 1946 by Isamu AMADA, the Japanese Group has attained a unique position in the industry. AMADA not only manufactures machine tools, but also comes up with and proposes technological solutions to support the competitive edge of its Customers. With over 70 years of activities and experience and more than 90 companies, AMADA stands for technology and reliability.
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