Cause: Incorrect Shank

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:

Significance 

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

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