136-2509 - Tuffaloy C-2509 Spot Welding Electrode #5 Taper Flat Face

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The Tuffaloy C-2509 Spot Welding Tip is a high-performance consumable designed for industrial resistance welding applications. Engineered to meet the rigorous standards of the Resistance Welder Manufacturers' Association (RWMA), this electrode is manufactured from Class 2 Chrome Copper alloy. Class 2 material is the industry standard for high-production spot welding of clean mild steel, low alloy steel, and stainless steel, offering an optimal balance of electrical conductivity and physical hardness. This ensures that the tip resists deformation (mushrooming) under the high compressive forces and thermal cycling inherent in the spot welding process.

This specific model features a #5 RWMA taper, which is a standard fit for 5/8-inch diameter electrode holders, ensuring broad compatibility with major resistance welding machinery. The "C" nose designation indicates a flat welding face, which in this configuration measures 1/4 inch in diameter. Flat-faced tips are frequently employed where surface indentation needs to be controlled or when welding heavier gauge materials where a concentrated current path is required without the deep penetration of a pointed tip. The 2-inch overall length provides standard reach, suitable for a wide variety of throat depths and fixture setups.

A distinguishing feature of Tuffaloy products is their proprietary passivation process. As noted in the product specifications, this treatment eliminates excessive oxidation on the copper surface, resulting in a bright, shiny finish. More importantly, this process ensures low initial contact resistance, allowing for consistent current transfer from the very first weld. By preventing the formation of insulating oxide layers during storage, Tuffaloy electrodes reduce the need for pre-cleaning and ensure reliable startup performance. The internal geometry is precision-drilled to accommodate water cooling tubes, ensuring efficient heat dissipation to prolong electrode life and maintain weld quality over extended production runs.