Resistance Welding Problems
Diagnose resistance welding defects quickly with our comprehensive visual issue database. Browse through common welding problems below to understand their characteristics, root causes, and proven repair methods.
Welding Issue and Cause Matrix
Missing Weld
Definition A weld is missing when there is no fusion of parent metal or coatings at the intended weld location.…
Undersized Weld
Definition The weld button/nugget diameter does not meet applicable specifications. (The weld nugget is the fused volume that joins the…
Stuck Weld
Definition Workpieces are held together by localized fusion at the welding interface, but no weld button is formed. Description Stuck…
Excessive Indentation
Definition Excessive Indentation occurs when the depression left by the electrode on the workpiece exceeds the manufacturer’s specification. Description Indentation…
Expulsion/Burn Through
Definition Expulsion is the forceful ejection of molten metal from the spot weld. Severe expulsion may eject enough material to…
Cracks & Holes
Definition Discontinuities within the weld nugget and/or surrounding area caused by metallurgical changes resulting from welding. Same as: Fissures (cracks),…
Mislocated/Edge Weld
Definition A weld that is incorrectly positioned compared to current workpiece design. Edge welds are those welds that touch or…
Sheet Metal Distortion
Definition The sheet metal is distorted if it is deformed such that the weld interface is out of the plane…
Extra Welds
Definition Additional welds on a workpiece compared to current workpiece design. Detection Detection is typically made with a visual inspection…
Inconsistent Spot Weld Quality
Definition Spot weld quality varies with some welds failing to meet applicable quality standards. Description Quality may vary as a…
Brittle Weld
Definition A resistance spot weld that fractures with little or no plastic deformation in either the weld or the surrounding…
Nonround Weld
Definition Welds or weld buttons are not circular. Description Non-round welds may be caused in several ways. Typically they are…
Poor Class A Appearance
Definition Visible weld features do not conform to the requirements of the applicable standard. Same as: Poor class I appearance,…
Sticking/Stuck Tips
Definition Sticking is a term that refers to the tendency of the electrode tip to adhere to the workpiece. Same…
Interfacial Separation
Definition The weld nugget splits along the original welding plane, rather than pulling a button. The weld zone shows evidence…