Cause: Wrong Shank

Definition
A shank of the wrong geometry and/or alloy.

Description
Shank: The current carrying electrode tip holder used when the tip is not inserted directly into the electrode adapter or welder arm (see figure).

Changing the shank from a male to a female tip or from a female to a male tip may change tip compatibility and/or the overall assembled length. Changing alloy material class will change the electrical and mechanical performance characteristics. Mismatched tapers will cause improper fit of the weld tips. Substituting a straight for an offset shank (or vice-versa) will change tip location relative to the other electrode. Overall length changes may create interferences or gaps between electrodes.

Detection
Wrong shank may have one or more of the following symptoms:

• Cracks & holes
• Excessive indentation
• Expulsion/burn through
• Mislocated edge weld
• Missing weld
• Nonround weld
• Poor Class A appearance
• Sheet metal distortion
• Stuck weld
• Undersized weld
• Excessive shank deflection
• Visual inspection of weld equipment and welds

Significance
Quality, Workplace Issues, Cost, Downtime, Maintenance, Throughput (cycle time; PPH), are all potentially affected by this condition.