Caps and Shanks tuffaloy-logo

5main

Tuffcap electrodes consist of two pieces: a shank and a replaceable cap. These two-part electrodes can offer major economies, because when the nose geometry is worn out, only the cap needs to be replaced. And it costs far less than a standard one-piece electrode. (A Tuffcap shank will normally outlast twenty caps.) Also, electrode inventory can be kept small because all nose designs will fit the same size shank.

TUFFALOY offers two kinds of Tuffcap electrodes. One uses a male cap that fits into the shank. The other has a female cap that fits over the shank.

FEMALE AND MALE CAPS are available in the widest range of sizes, alloys, and styles. They are made in both Class 1 and Class 2 alloy, and in sizes to fit- shanks sized 4 through 7 RW. Male caps are more effectively cooled than female caps.

ALL CAPS are made with the same nose designs in conformance with RWMA standards.

MALE AND FEMALE SHANKS are made of Class 2 alloy, either straight, or bent to provide an offset. Shanks other than those cataloged can be special ordered. Tuffcap, caps and shanks should be used only in a directly opposed, straight-line manner. They do not work as well as standard electrodes on heavily coated metal such as galvanized or tin-plate.

TUFFTRODE-Z CAPS FOR COATED STEELS To avoid electrode sticking problems common when welding galvanized and aluminized materials, these copper chrome-zirconium alloy caps are offered. They give the same performance as dispersion-strengthened caps but cost far less. They are Class 2 caps in mechanical and physical properties. Both male and female caps are offered in all the standard nose designs.

NEW! SUPER NOSE DESIGN CAPS

To avoid mushrooming and brassing problems associated with standard designs, these caps have a self-dressing weld face ring that acts as a control zone. The Super Nose caps are available in TUFFALOY’s new “Z” material, that eliminates electrode sticking problems common when welding galvanized and aluminized materials. Both male and female designs are offered, designed to fit shanks with 5 RW taper.

U.S. Patent Number 5,155,320

Other patents pending

6.3.1
Pointed Nose Male Cap (A)
RWMA Alloy Class No.Part NumberPart DescriptionRWMA Male Cap Taper No.Major Diameter (in)Overall Length (in)Weld Face Diameter (in)Water Hole Diameter (in)Water Hole Depth (in)
TABCDE
1111-0014TA-1441/21-1/83/169/320.48
2 (CuCr)112-0024TA-2441/21-1/83/169/320.48
2 (CuCrZr)126-0024TA-24Z41/21-1/83/169/320.48
3122-1034TA-3441/21-1/83/169/320.48
1111-0015TA-1555/81-1/41/45/160.78
2 (CuCr)112-0025TA-2555/81-1/41/45/160.78
2 (CuCr)112-0022TA-2255/81-1/41/45/160.59
2 (CuCrZr)126-0025TA-25Z55/81-1/41/45/160.78
3122-1035TA-3555/81-1/41/45/160.78
1111-0016TA-1663/41-5/89/323/80.89
2 (CuCr)112-0026TA-2663/41-5/89/323/80.89
2 (CuCrZr)126-0226TA-26Z63/41-5/89/323/80.89
1111-0017TA-1777/81-5/85/161/20.79
2 (CuCr)112-0027TA-2777/81-5/85/161/20.79
6.3.2
Dome Nose Male Cap (B)
RWMA Alloy Class No.Part NumberPart DescriptionRWMA Male Cap Taper No.Major Diameter (in)Overall Length (in)Weld Face Diameter (in)Water Hole Diameter (in)Water Hole Depth (in)
TABCDE
1113-0014TB-1441/21-1/83/169/320.48
2 (CuCr)114-0024TB-2441/21-1/83/169/320.48
1113-0015TB-1555/81-1/41/45/160.78
2 (CuCr)114-0025TB-2555/81-1/41/45/160.78
2 (CuCrZr)126-0026TB-25Z55/81-1/41/45/160.78
2 (CuCrZr)126-0026-.20TB-25Z-.2055/81-1/43/165/160.78
2 (CuCrZr)511-TB-25Z-NFTB-25Z-NF55/81-1/4Full Dome5/160.78
1113-0016TB-1663/41-5/89/323/80.89
2 (CuCr)114-0026TB-2663/41-5/89/323/80.89
1113-0017TB-1777/81-5/85/161/20.79
2 (CuCr)114-0027TB-2777/81-5/85/161/20.79
6.3.3
Flat Nose Male Cap (C)
RWMA Alloy Class No.Part NumberPart DescriptionRWMA Male Cap Taper No.Major Diameter (in)Overall Length (in)Water Hole Diameter (in)Water Hole Depth (in)
TABDE
1115-0014TC-1441/21-1/89/320.48
2 (CuCr)116-0024TC-2441/21-1/89/320.48
2 (CuCrZr)126-0044TC-24Z41/21-1/89/320.48
3122-3034TC-3441/21-1/89/320.48
1115-0015TC-1555/81-1/45/160.78
2 (CuCr)116-0025TC-2555/81-1/45/160.78
2 (CuCrZr)126-0027TC-25Z55/81-1/45/160.78
3122-3035TC-3555/81-1/45/160.78
1115-0016TC-1663/41-5/83/80.89
2 (CuCr)116-0026TC-2663/41-5/83/80.89
1115-0017TC-1777/81-5/81/20.79
2 (CuCr)116-0027TC-2777/81-5/81/20.79
6.3.2
Offset Nose Male Cap (D)
RWMA Alloy Class No.Part NumberPart DescriptionRWMA Male Cap Taper No.Major Diameter (in)Overall Length (in)Weld Face Diameter (in)Water Hole Diameter (in)Water Hole Depth (in)
TABCDE
1117-0014TD-1441/21-1/83/169/320.48
2 (CuCr)118-0024TD-2441/21-1/83/169/320.48
2 (CuCrZr)126-0054TD-24Z41/21-1/83/169/320.48
3122-4034TD-3441/21-1/83/169/320.48
1117-0015TD-1555/81-1/41/45/160.78
2 (CuCr)118-0025TD-2555/81-1/41/45/160.78
2 (CuCrZr)126-0028TD-25Z55/81-1/41/45/160.78
3122-4035TD-3555/81-1/41/45/160.78
1117-0016TD-1663/41-5/89/323/80.89
2 (CuCr)118-0026TD-2663/41-5/89/323/80.89
1117-0017TD-1777/81-5/85/161/20.79
2 (CuCr)118-0027TD-2777/81-5/85/161/20.79
6.3.5
Truncated Nose Male Cap (E)
RWMA Alloy Class No.Part NumberPart DescriptionRWMA Male Cap Taper No.Major Diameter (in)Overall Length (in)Weld Face Diameter (in)Water Hole Diameter (in)Water Hole Depth (in)
TABCDE
1119-0014TE-1441/21-1/83/169/320.48
2 (CuCr)119-0024TE-2441/21-1/83/169/320.48
2 (CuCrZr)126-0064TE-24Z41/21-1/83/169/320.48
1119-0015TE-1555/81-1/41/45/160.78
2 (CuCr)119-0025TE-2555/81-1/41/45/160.78
2 (CuCrZr)126-0029TE-25Z55/81-1/41/45/160.78
2 (CuCr)119-0026TE-2663/41-5/89/323/80.89
2 (CuCr)119-0027TE-2777/81-5/85/161/20.79
6.3.6
Radius Nose Male Cap (F)
RWMA Alloy Class No.Part NumberPart DescriptionRWMA Male Cap Taper No.Major Diameter (in)Overall Length (in)Weld Face Diameter (in)Water Hole Diameter (in)Water Hole Depth (in)
TABCDE
1119-0114TF-1441/21-1/829/320.48
2 (CuCr)119-0124TF-2441/21-1/829/320.48
1119-0115TF-1555/81-1/425/160.78
2 (CuCr)119-0125TF-2555/81-1/425/160.78
2 (CuCr)119-0126TF-2663/41-5/82-3/43/80.89
1119-0117TF-1777/81-5/861/20.79
2 (CuCr)119-0127TF-2777/81-5/861/20.79
6.3.7
Super Nose (Self Dressing) Male Cap (S)
RWMA Alloy Class No.Part NumberPart DescriptionRWMA Male Cap Taper No.Major Diameter (in)Overall Length (in)Weld Face Diameter (in)Water Hole Diameter (in)Water Hole Depth (in)
TABCDE
2 (CuCr)127-0024TS-24Z41/21-1/83/169/320.48
2 (CuCr)127-0025TS-25Z55/81-1/41/45/160.78

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