Weld Wrongly LocatedDefinition
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-upDefinition
The electrode tips do not move towards each other quickly enough during the forging phase of the weld sequence.
Description
During...
Incorrect Workpiece SelectedDefinition
A workpiece that does not conform to the relevant bill of material, blueprint, specifications, etc.
Description
The following are...
Incorrect Test ProcedureDefinition
Not following the specified test procedure for determining the characteristics of a resistance weld.
Description
The following are...
Inadequate or No Gun EqualizationDefinition
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 WorkpieceDefinition
Resistance welding electrode faces not parallel to workpiece after tips have been closed.
Description
Line joining center points of...
Weld Flange Too SmallDefinition
The width of the weld flange is inadequate to allow proper placement of the weld.
Description
Weld flange widths are subject to company...
Damaged PartDefinition
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-upDefinition
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 SealerDefinition
Too much sealer or adhesive is applied, or it is applied in the wrong location, such that weld quality is...
Dirty MaterialDefinition
A workpiece surface that is not free of substances that will degrade the welding operation.
Description
Dirty material or surface...
Incorrect Material/CoatingDefinition
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 PartsDefinition
The phenomenon of the secondary current bypasses the nugget being formed is called shunting.
Description
Since shunting always reduces...
Poor Weld AccessibilityDefinition
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/ShuntsDefinition
The weld is not correctly made due to the use of an incorrect cable or shunt.
Description
Cross Sectional...
Wrong TransformerDefinition
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 ConnectionsDefinition
Poor electrical connections are the joints, in either the high or low voltage side of the welding circuit that are not properly...
Incorrect HosesDefinition
Hoses do not allow proper flow, pressure, or range of motion.
Description
Hoses provide the fluid (air, oil, water, etc.) flow path for...
Incorrect CylinderDefinition
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 SystemDefinition
A faulty air or hydraulic system is one which adversely affects the electrode motion, follow-up, or force...
Poor Mechanical ConnectionDefinition
Weld system components are loose due to wear or improperly applied fasteners.
Description
Correct replacement parts and procedures...
Insufficient CoolingDefinition
The coolant flow rate is below, or temperature is above, the nameplate rating for the resistance welding component.
Description
The...
Wrong ShankDefinition
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 DressingDefinition
Electrode dressing is a manual or automated operation to reshape electrodes or resurface their uneven faces after they have become...
Electrode Skidding/SlidingDefintion: Electrode Skidding /Sliding and possible solutions.
When the electrodes touch the sheet metal, they may move a short distance along the...
Electrode WearDefinition : Electrode wear is a deformation of the tip face over time due to the resistance welding process.
Same as: Electrode...
Inadequate Electrode AlignmentDefinition
In welding position, improper electrode alignment exists when either of the two conditions is true:
The contact surfaces of the upper...
Wrong TipsDefinition
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 LongDefinition
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 ShortDefinition
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 ShortDefinition
Squeeze time is the period of time programmed into the weld controller, typically between the command to close the electrode and...
Weld Time LongDefinition
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 ShortDefinition
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 HighDefinition
The interfacial welding force is more than that required by the applicable specification.
Description
Weld force brings the metal...
Weld Force LowDefinition
The interfacial welding force is less than that required by the applicable specification.
Description
Weld force brings the metal...
Weld Current HighDefinition
The current passed through during the weld and time is too long for the welding conditions.
Same as: over-current condition, hot...
Weld Current LowDefinition
The applied weld current is insufficient at the existing conditions to form an acceptable weld. Same as: low heat, cold...
