A resistance spot welding system includes an electrode with a cap that includes a cap body having a tip, a body cavity defined within the cap body, and a tip cavity defined within the cap body that extends from the body cavity towards the tip. A method of manufacturing the electrode includes forming a body cavity within a cap body of the electrode, and forming a tip cavity within the cap body of the electrode such that the tip cavity extends from the body cavity towards a tip of the cap body. In other aspects, a resistance spot welding system includes a first electrode, a second electrode, and an external cooling unit that is configured to inject a coolant adjacent to at least one of the first electrode and the second electrode during welding.
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Lin, Dechao; Zhu, Dewei; Wu, Zhuoru; Liang, Zeqin; Malpica, Julio; Simon, Joerg; and Bezencon, Cyrille, "Electrode with Tip Life Improvement and Related Methods", Technical Disclosure Commons, (May 08, 2020)