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 are noted below:

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