The short lifespan and frequent machine downtime because of wear of copper electrodes in resistance welding are major issue in fin-tube welding for waste heat recovery boilers. To address this, a Cu–Cr–Zr alloy was developed as an alternative to electrolytic tough pitch (ETP)-Copper electrodes for H-type fin welding. The alloy was synthesized by melting electrolytic copper, chromium powder, and zirconium chips at 1,100°C–1,300°C, followed by hot forging and aging at 450°C for 120 min. This process significantly improved the alloy’s microstructure, mechanical properties, and electrical conductivity. The Cu–Cr–Zr alloy achieved a tensile strength of 426 MPa, elongation above 18 %, and electrical conductivity over 86.5 % International Annealed Copper Standard. Microstructural analysis revealed fine, equiaxed grains from multistage deformation and aging, enhancing grain boundary density and reducing lattice distortion, which improved conductivity. In performance tests, the Cu–Cr–Zr alloy’s lifespan is 20 times longer than that of ETP-Cu in H-type fin-to-tube welding.