Issues

Welding Help is a user-friendly, computer-based tool for anyone seeking information on specific resistance welding issues. It will help anyone from those with plant floor welding responsibility, to newcomers wanting to learn more about welding.

WeldHelp uses weld issues - specific abnormalities seen in spot welds, and POSSIBLE CAUSES - situations involving equipment, materials, methods or operators that could lead to these abnormalities.


Interfacial Separation Definition The weld nugget splits along the original welding plane, rather than pulling a button. The weld zone shows evidence of adequate fusion...
Sticking/Stuck Tips Definition Sticking is a term that refers to the tendency of the electrode tip to adhere to the workpiece. Same as: pick-up. Description Elevated...
Poor Class A Appearance Definition Visible weld features do not conform to the requirements of the applicable standard. Same as: Poor class I appearance, poor cosmetic weld...
Nonround Weld Definition Welds or weld buttons are not circular. Description Nonround welds may be caused in several ways. Typically they are the result of...
Brittle Weld Definition A resistance spot weld that fractures with little or no plastic deformation in either the weld or the surrounding...
Inconsistent Weld Quality Definition Weld quality varies with some welds failing to meet applicable quality standards. Description Quality may vary as a result of a trend...
Extra Welds Definition Additional welds on a workpiece compared to current workpiece design. Detection Detection is typically made with a visual inspection of...
Sheet Metal Distortion Definition The sheet metal is distorted if it is deformed such that the weld interface is out of the plane of the sheet metal, or if any of the...
Mislocated/Edge Weld Definition A weld that is incorrectly positioned compared to current workpiece design. Edge welds are those welds that touch or extend beyond the...
Cracks and Holes Definition Discontinuities within the weld nugget and/or surrounding area caused by metallurgical changes resulting from welding. Same as: Fissures...
Expulsion/Burn Through Definition Expulsion is the forceful ejection of molten metal from the weld. Severe expulsion may eject enough material to create a through-hole in...
Excessive Indentation Definition Excessive Indentation occurs when the depression left by the electrode on the workpiece exceeds the manufacturer’s...
Stuck Weld Definition Workpieces are held together by localized fusion at the welding interface, but no weld button is formed. Description Stuck welds occur...
Undersized Weld Definition The weld button/nugget diameter does not meet applicable specifications. (The weld nugget is the fused volume that joins the workpieces....
Missing Weld Definition A weld is missing when there is no fusion of parent metal or coatings at the intended weld location. Description Missing welds can...