Poor Class A Appearance


Visible weld features do not conform to the requirements of the applicable standard.
Same as: Poor class I appearance, poor cosmetic weld appearance.


Spot welds are typically classified both in terms of their functional requirements and their surface appearance. The most stringent cosmetic stipulation is for the appearance of a surface (usually customer-visible) to be free from markings or imperfections such that a weld is not visible after painting. Other requirements may limit the displacement, indentation, or distortion of the parent metal. These criteria are normally specified as a percentage of the governing metal thickness. Weld flash may also be specified as unacceptable.


Detection is normally by visual inspection of the weld surface. Measurements may be required on marginal indentation or displacement calls.


Quality, Workplace Issues, Cost, Downtime, Maintenance, Throughput (cycle time; PPH), are all potentially affected by this condition. Special considerations are noted below:

  • Quality: Welds not satisfying the appearance requirement may adversely affect the function of seals, fit of trim, customer quality perception etc.

Possible Causes

Strong Possibilities

Weak Possibilities