Electrode Holder Design

The electrode holder clamps the end of the electrode with conductive clamps built into its head. These clamps operate through either:

Twist action mechanism
Spring-loaded clamp action (crocodile type)

The clamping mechanism allows for the quick release of the remaining unused electrode end (stub end).

Ensuring Welding Efficiency

To ensure maximum welding efficiency, the electrode must be firmly clamped into the holder. Poor electrical contact may cause:

Arc instability through voltage fluctuations
Overheating of the holder

Mechanical

Direct mechanical connection

Crimped

Pressure-formed connection

Soldered

Heat-bonded connection

All electrode holders should conform to IEC 60974-11.

Cable Connections and Safety

It is essential to ensure all connections are secure between electrode, holder, and cable. Poor connections can lead to:

Resistance heating
In severe cases, minor arcing with the torch body
Holder overheating

Welding Circuit Components

The complete welding circuit includes two main cables from the power source:

Welding Lead

Connects to the electrode holder

Work Return Lead

Clamps to the workpiece

Note: A separate earth lead may be required to provide protection from faults in the power source. This earth cable should be capable of carrying the maximum output current of the power source.

Cable Construction

Welding cables feature:

Smooth and hard-wearing protective flexible sheath
Either rubberized or PVC material conforming to relevant standards
Oil and water resistant coating
Electrical insulation at voltages to earth not exceeding 100V DC and AC (rms value)

Cable Selection Criteria

Welding cable diameter is selected based on welding current level. Higher current and duty cycle require larger diameter cables to prevent overheating.

For welding operations conducted at a distance from the power source, increased cable diameter may be necessary to reduce voltage drop.

Nominal cross sectional area (mm²)	Maximum dia of conductor wire (mm)	Thickness of covering (mm)	Mean overall diameter (mm)	Maximum conductor resistance at 20°C (Ø/km)	Capacity at 60% duty cycle (Amperes)
16	0.31	1.8	8.2	1.21	175
25	0.31	2.0	10.2	0.780	230
35	0.31	2.2	12.0	0.554	290
50	0.31	2.4	13.5	0.386	365
70	0.31	2.6	15.6	0.272	460
90	0.31	2.8	18.2	0.206	560
120	0.31	3.0	20.4	0.161	650

Knowledge Center

The Electrode Holder and Cables