Causes of Poor Resistance Welds
Identify and resolve resistance welding problems by selecting a specific cause below. Each entry provides detailed explanations of welding issues, their root causes, and proven solutions to improve your weld quality and production efficiency.
Electrode Wear
Definition : Electrode wear is a deformation of the tip face over time due to the resistance welding process. Same as:…
Incorrect Material/Coating
Definition The material to be welded has a different base chemistry, processing, or coating than that specified for the part.…
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,…
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…
Poor Electrical Connections
Definition Poor electrical connections are the joints, in either the high or low voltage side of the welding circuit that…
Incorrect Hoses
Definition Hoses do not allow proper flow, pressure, or range of motion. Description Hoses provide the fluid (air, oil, water,…
Incorrect Cylinder
Definition The weld cylinder will not provide the proper range of electrode force or motion. Description The weld cylinder serves…
Defective Air or Hydraulic System
Definition A faulty air or hydraulic system is one which adversely affects the electrode motion, follow-up, or force application. Description…
Poor Mechanical Connection
Definition Weld system components are loose due to wear or improperly applied fasteners. Description Correct replacement parts and procedures should…
Insufficient Cooling
Definition The coolant flow rate is below, or temperature is above, the nameplate rating for the resistance welding component. Description…
Wrong Shank
Definition A shank of the wrong geometry and/or alloy. Description Shank: The current carrying electrode tip holder used when the…
Incorrect Electrode Tip Dressing
Definition Electrode dressing is a manual or automated operation to reshape electrodes or resurface their uneven faces after they have…
Electrode Skidding/Sliding
Definition When the electrodes touch the sheet metal, they may move a short distance along the metal surface. This is…
Dirty Material
Definition A workpiece surface that is not free of substances that will degrade the welding operation. Description Dirty material or…
Electrode Misalignment
Definition In welding position, electrode misalignment exists when either of the two conditions is true: The contact surfaces of the…
Wrong Electrode Tips
Definition One or both of the electrode tips installed is not of the design or material intended for the application.…
Long Hold Time
Definition Hold time is the amount of time programmed into the weld controller, typically between the end of weld time…
Short Hold Time
Definition Hold time is the period of time programmed into the weld controller, typically between the end of weld time…
Short Squeeze Time
Definition Squeeze time is the period of time programmed into the weld controller, typically between the command to close the…
Long Weld Time
Definition For a typical weld, weld time is the amount of time welding current flows through the metal. Weld time…
Short Weld Time
Definition For a typical weld, weld time is the amount of time welding current flows through the metal. Weld time…
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…
Weld Current Low
Definition The applied weld current is insufficient at the existing conditions to form an acceptable weld. Same as: low heat,…
Excessive Sealer
Definition Too much sealer or adhesive is applied, or it is applied in the wrong location, such that weld quality…
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…
Damaged Part
Definition The weld is not correctly made due to the use of a flawed workpiece. Description The weld is not…
Weld Flange Too Small
Definition The width of the weld flange is inadequate to allow proper placement of the weld. Description Weld flange widths…
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…
Inadequate or No Weld Gun Equalization
Definition The weld gun is not able to close on the workpiece with approximately equal force on each tip. Description…
Incorrect Test Procedure
Definition Not following the specified test procedure for determining the characteristics of a resistance weld. Description The following are examples…
Incorrect Workpiece Selected
Definition A workpiece that does not conform to the relevant bill of material, blueprint, specifications, etc. Description The following are…
Poor Electrode Follow-up
Definition The electrode tips do not move towards each other quickly enough during the forging phase of the weld sequence.…
Weld Wrongly Located
Definition The weld has been placed in the wrong location on the part, or has been omitted completely. Description Assembly…