Cause: Insufficient Cooling

The coolant flow rate is below, or temperature is above, the nameplate rating for the resistance welding component.


The cooling requirements of a resistance welding component are defined by rate, temperature, and sometimes direction.

The minimum rate of the coolant flow is given on the nameplate of the component in either gpm (gallons per minute) or lpm (liters per minute).

The maximum temperature for the coolant is given on the nameplate of the component.

Certain components (e.g., tips) may require a specific coolant flow direction.


Detection evidence may include:


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

Maintenance: The life of components requiring coolant can be significantly reduced by the lack of cooling. Operating the component with insufficient cooling can damage or destroy it.

Subordinate Causes

  • Plugged filters in cooling system
  • Failed in cooling system flow valves
  • Inadequate flow rates or pressure in series/parallel components within the cooling system
  • Buildup of deposits within the cooling path

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