Cause

Weld Wrongly Located Definition The weld has been placed in the wrong location on the part, or has been omitted completely. Description Assembly weld locations do not...
Poor Electrode Follow-up Definition The electrode tips do not move towards each other quickly enough during the forging phase of the weld sequence. Description During...
Incorrect Workpiece Selected Definition A workpiece that does not conform to the relevant bill of material, blueprint, specifications, etc. Description The following are...
Incorrect Test Procedure Definition Not following the specified test procedure for determining the characteristics of a resistance weld. Description The following are...
Inadequate or No Gun Equalization Definition The welder is not able to close on the workpiece with approximately equal force on each tip. Description An equalizing system...
Electrode Face Not Parallel to Workpiece Definition Resistance welding electrode faces not parallel to workpiece after tips have been closed. Description Line joining center points of...
Weld Flange Too Small Definition The width of the weld flange is inadequate to allow proper placement of the weld. Description Weld flange widths are subject to company...
Damaged Part Definition The weld is not correctly made due to the use of a flawed workpiece. Description The weld is not properly made due to the workpiece not...
Poor or Varying Part Fit-up Definition Fit-up is defined as a measure of the closeness or degree of contact between mating parts. Description The metal being welded does not...
Excessive Sealer Definition Too much sealer or adhesive is applied, or it is applied in the wrong location, such that weld quality is...
Dirty Material Definition A workpiece surface that is not free of substances that will degrade the welding operation. Description Dirty material or surface...
Incorrect Material/Coating Definition The material to be welded has a different base chemistry, processing, or coating than that specified for the part. Description The...
Shunting of Guns or Parts Definition The phenomenon of the secondary current bypasses the nugget being formed is called shunting. Description Since shunting always reduces...
Poor Weld Accessibility Definition Poor weld accessibility is inadequate gun access to the proper weld spot location on the part or welded flange, touching only at the...
Wrong Cables/Shunts Definition  The weld is not correctly made due to the use of an incorrect cable or shunt. Description  Cross Sectional...
Wrong Transformer Definition The weld is not correctly made due to the use of an improper transformer. Description Transformer size is defined by both the secondary...
Poor Electrical Connections Definition Poor electrical connections are the joints, in either the high or low voltage side of the welding circuit that are not properly...
Incorrect Hoses Definition Hoses do not allow proper flow, pressure, or range of motion. Description Hoses provide the fluid (air, oil, water, etc.) flow path for...
Incorrect Cylinder Definition The weld cylinder will not provide the proper range of electrode force or motion. Description The weld cylinder serves two primary...
Defective Air or Hydraulic System Definition A faulty air or hydraulic system is one which adversely affects the electrode motion, follow-up, or force...
Poor Mechanical Connection Definition Weld system components are loose due to wear or improperly applied fasteners. Description Correct replacement parts and procedures...
Insufficient Cooling Definition The coolant flow rate is below, or temperature is above, the nameplate rating for the resistance welding component. Description The...
Wrong Shank Definition A shank of the wrong geometry and/or alloy. Description Shank: The current carrying electrode tip holder used when the tip is not...
Incorrect Electrode Dressing Definition Electrode dressing is a manual or automated operation to reshape electrodes or resurface their uneven faces after they have become...
Electrode Skidding/Sliding Defintion: Electrode Skidding /Sliding and possible solutions. When the electrodes touch the sheet metal, they may move a short distance along the...
Electrode Wear Definition : Electrode wear is a deformation of the tip face over time due to the resistance welding process.  Same as: Electrode...
Inadequate Electrode Alignment Definition In welding position, improper electrode alignment exists when either of the two conditions is true: The contact surfaces of the upper...
Wrong Tips Definition One or both of the electrode tips installed is not of the design or material intended for the application. Same as: wrong caps, improper...
Hold Time Long Definition Hold time is the amount of time programmed into the weld controller, typically between the end of weld time and the command to open the...
Hold Time Short Definition Hold time is the period of time programmed into the weld controller, typically between the end of weld time and the command to open the...
Squeeze Time Short Definition Squeeze time is the period of time programmed into the weld controller, typically between the command to close the electrode and the...
Weld Time Long Definition For a typical weld, weld time is the amount of time welding current flows through the metal. Weld time is long when it exceeds applicable...
Weld Time Short Definition For a typical weld, weld time is the amount of time welding current flows through the metal. Weld time short is when weld current is...
Weld Force High Definition The interfacial welding force is more than that required by the applicable specification. Description Weld force brings the metal...
Weld Force Low Definition The interfacial welding force is less than that required by the applicable specification. Description Weld force brings the metal...
Weld Current High Definition The current passed through during the weld and time is too long for the welding conditions. Same as: over-current condition, hot...
Weld Current Low Definition The applied weld current is insufficient at the existing conditions to form an acceptable weld. Same as: low heat, cold...