Stuck Weld


Workpieces are held together by localized fusion at the welding interface, but no weld button is formed.


Stuck welds occur when there is insufficient heat at the welding interface to bring about nugget growth. Instead, fusion occurs only between point contacts between the sheets. With coated materials, coatings can melt and refreeze, effectively soldering the parts together. The resulting bonds are strong enough to hold the workpieces together under light loads, but reasonable force will pull them apart.


Pry testing or teardown will detect stuck welds.


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

Possible Causes

Strong Possibilities

Weak Possibilities