Electrode beam welded spark plugs for industrial electrodes

1. A spark plug for providing a spark to ignite a combustible mixture in a combustion chamber, comprising:

a central electrode including a central base extending longitudinally from a terminal end to a central base end,

a ground electrode including a ground base extending from a shell end to a ground base end,

said central electrode and said ground electrode presenting a spark gap therebetween,

at least one of said electrodes including a firing tip having a tip end disposed adjacent said base end,

said firing tip including opposite tip sides extending continuously from said tip end to a firing end providing said spark gap,

said firing tip presenting a tip diameter extending between said opposite tip sides and a tip thickness extending from said tip end to said firing end,

the spark plug being formed by a process comprising the steps of: providing said firing tip with an aspect ratio of 4.736 to 8.0 and electron beam welding said firing tip to said electrode base,

said electrode including an electron beam weld between said electrode base and said tip end of said firing tip, wherein said aspect ratio of said firing tip is determined by dividing said tip diameter before welding said firing tip to said electrode base by said tip thickness before welding said firing tip to said electrode base, and

said electron beam weld extending continuously between said opposite tip sides.

2. The spark plug of claim 1 wherein said firing tip presents a tip welding surface extending continuously between said opposite tip sides at said tip end and said electron beam weld extends continuously over said tip welding surface.

3. The spark plug of claim 1 wherein said firing tip includes an iridium-based material including iridium in an amount of at least 70.0 wt. %, based on the total weight of said iridium-based material.

4. The spark plug of claim 3 wherein said iridium-based material includes iridium in an amount of at least 95.0 wt. %, rhodium in an amount of 1.0 to 3.0 wt. %, tungsten in an amount of 0.1 to 0.5 wt. %, and zirconium in an amount of 0.01 to 0.03 wt. %, based on the total weight of said iridium-based material.

5. The spark plug of claim 1 wherein said electrode base includes a nickel-based material including nickel in an amount of at least 60.0 wt. %, based on the total weight of said nickel-based material.

6. The spark plug of claim 1 wherein said electrode base is formed of a nick-based material including nickel in an amount of at least 60.0 wt. %, based on the total weight of said nickel-based material, and said firing tip is formed of an iridium-based material, including iridium in an amount of at least 60.0 wt. %, based on the total weight of said iridium-based material, said electron beam weld includes a mixture of said nickel-based material and said iridium-based material, and said mixture extends continuously between said opposite tip sides.

7. The spark plug of claim 6 wherein said nickel-based material and said iridium-based material of said electron beam weld is re-crystallized.

8. The spark plug of claim 7 wherein said electron beam weld includes said re-crystallized nickel-based material and said re-crystallized iridium-based material each in an amount of at least 30% wt. %, based on the total weight of said electron beam weld.

9. The spark plug of claim 1 wherein said tip thickness is 0.02 to 0.03 inches.

10. The spark plug of claim 1 wherein said tip diameter is 0.1184 to 0.1776 inches.

11. The spark plug of claim 1 wherein said aspect ratio of said firing tip is 4.736 to 7.104.

12. A spark plug for providing a spark to ignite a combustible mixture of fuel and air of combustion chamber, comprising:

a central electrode including a central base extending longitudinally from a terminal end to a central base end,

said central base being formed of a nickel-based material including nickel in an amount of at least 60.0 wt. %, based on the total weight of said nickel-based material,

a ground electrode including a ground base extending from a shell end to a ground base end,

said ground base being formed of a nickel-based material including nickel in an amount of at least 60.0 wt. %, based on the total weight of said nickel-based material,

said central electrode and said ground electrode presenting a spark gap therebetween,

at least one of said electrodes including a firing tip having a tip end disposed adjacent said base end,

said firing tip including opposite tip sides extending longitudinally from said tip end to a firing end at said spark gap,

said firing tip presenting a tip welding surface extending continuously between said opposite tip sides at said tip end,

said firing tip having a tip thickness extending from said tip end to said firing end, wherein said tip thickness is 0.02 to 0.03 inches,

said firing tip having a tip diameter extending between said opposite tip sides, wherein said tip diameter is 0.1184 to 0.1776 inches,

the spark plug being formed by a process comprising the steps of: providing said firing tip with an aspect ratio of 4.736 to 7.104 and electron beam welding said firing tip to said electrode base,

said firing tip being formed of an iridium-based material including iridium in an amount of at least 95.0 wt. %, %, rhodium in an amount of 1.0 to 3.0 wt. %, tungsten in an amount of 0.1 to 0.5 wt. %, and zirconium in an amount of 0.01 to 0.03 wt. %, based on the total weight of said iridium-based material,

said electrode including an electron beam weld between said electrode base and said firing tip, wherein said aspect ratio of said firing tip is determined by dividing said tip diameter before welding said firing tip to said electrode base by said tip thickness before welding said firing tip to said electrode base,

said electron beam weld extending continuously between said opposite tip sides and continuously over said tip welding surface,

said electron beam weld including a mixture of said nickel-based material and said iridium-based material,

said nickel-based material and said iridium-based material of said electron beam weld being re-crystallized, and

said electron beam weld including said re-crystallized iridium-based material and said re-crystallized nickel-based material each in an amount of at least 30% wt. %, based on the total weight of said electron beam weld.

13. An electrode for use in a spark plug, comprising:

a base extending to a base end,

said electrode including a firing tip having a tip end disposed adjacent said base end,

said firing tip including opposite tip sides extending continuously from said tip end to a firing end,

said firing tip presenting a tip diameter extending between said opposite tip sides and a tip thickness extending from said tip end to said firing end,

the electrode being formed by a process comprising the steps of: providing said firing tip with an aspect ratio of 4.736 to 8.0 and electron beam welding said firing tip to said base,

said electrode including an electron beam weld between said electrode base and said tip end of said firing tip, wherein said aspect ratio of said firing tip is determined by dividing said tip diameter before welding said firing tip to said electrode base by said tip thickness before welding said firing tip to said electrode base, and

said electron beam weld extending continuously between said opposite tip sides.

14. The electrode of claim 13 wherein said firing tip presents a tip welding surface extending continuously between said opposite tip sides at said tip end and said electron beam weld extends continuously over said tip welding surface.

15. The electrode of claim 13 wherein said firing tip includes an iridium-based material including iridium in an amount of at least 70.0 wt. %, based on the total weight of said iridium-based material.

16. The electrode of claim 13 wherein said electrode base is formed of a nick-based material including nickel in an amount of at least 60.0 wt. %, based on the total weight of said nickel-based material, and said firing tip is formed of an iridium-based material, including iridium in an amount of at least 60.0 wt. %, based on the total weight of said iridium-based material, said electron beam weld includes a mixture of said nickel-based material and said iridium-based material, and said mixture extends continuously between said opposite tip sides.

17. The electrode of claim 16 wherein said nickel-based material and said iridium-based material of said electron beam weld is re-crystallized.

18. The electrode of claim 13 wherein said tip thickness is 0.02 to 0.03 inches.

19. The electrode of claim 13 wherein said tip diameter is 0.1184 to 0.1776 inches.

20. The electrode of claim 13 wherein said aspect ratio of said firing tip is 4.736 to 7.104.

21. A spark plug for providing a spark to ignite a combustible mixture in a combustion chamber, comprising:

a central electrode including a central base extending longitudinally from a terminal end to a central base end,

a ground electrode including a ground base extending from a shell end to a ground base end,

said central electrode and said ground electrode presenting a spark gap therebetween,

at least one of said electrodes including a firing tip having a tip end disposed adjacent said base end,

said firing tip including opposite tip sides extending continuously from said tip end to a firing end providing said spark gap,

said electrode including an electron beam weld between said electrode base and said tip end of said firing tip,

said electron beam weld extending continuously between said opposite tip sides, and

said electron beam weld having a weld thickness of 0.015 to 0.035 inches.