weldhelp_matrix_tease.jpg (208x139)Issue/Cause Chart
Use this matrix as a quick reference to link common welding issues with standard causes (Interactive and printable PDF). 

Missing WeldMissing Weld
Missing welds may be the result of operator placement mistakes, or the result of machine errors in performance or settings. 

Undersized WeldUndersized Weld
Undersized welds can be the product of dirty or damaged parts and materials or incorrect welding set-ups. 

Stuck WeldStuck Weld
Electrode wear, low weld current and high weld force may cause "stuck welds," when only a slight, weak bond is formed. 

Excessive IndentationExcessive Indentation
High weld current, high weld force and long squeeze and hold times may cause deep indentations that exceed specifications. 

Expulsion or Burn-ThroughExpulsion/Burn-Through
Issues with electrode follow-up, high current and small weld flanges can cause the expulsion of molten metal during welds. 

Welding Cracks and HolesCracks and Holes
High current, low force, expulsion and other systematic problems may cause cracks and holes in welds. 

Mislocated/Edge WeldsMislocated/Edge Welds
Edge welds are often the result of electrode misplacement, trouble with access to weld areas, or part defects. 

Sheet Metal DistortionSheet Metal Distortion
Problems with weld force, fixture placement and access to weld areas may cause distortion in workpieces and stampings. 

Extra WeldsExtra Welds
Additional unintended welds are usually the result of incorrect workpieces or operator, robot or fixture error. 

wh_inconsistent_3x2.jpg (208x139)Inconsistent Welds
Variances in workpieces and uneven electrical or mechanical connections may cause inconsistent resistance welds. 

Brittle WeldsBrittle Welds
A weld that fractures with little plastic deformation may be caused by long hold times or problems with workpiece chemistry. 

Non-Round WeldsNon-Round Welds
Non-round welds may be caused by electrode wear, issues with tip alignment or dirty workpieces. 

Poor Class A AppearancePoor Class A Appearance
Issues with Class A appearance are often concurrent with a number of other issues, such as consistency and quality. 

wh-stuckelectrode.jpg (208x139)Stuck Electrodes
Electrodes and workpieces may alloy after long hold times, or incorrect workpiece materials or coatings. 

wh_interfacialseparation_3x2.jpg (208x138)Interfacial Separation
Separation along the original weld plane (rather than a weld button) may occur when workpieces are stronger than the weld nugget. 

Resistance Spot Welding Defect Troubleshooting Guide

The WeldHelp Resistance Welding Troubleshooting Guide is written for operators and engineers to help diagnose and solve common spot welding defects and issues, projection welding and seam welding applications. Consider it an experienced second opinion in a specialized field. Select an issue above or, if you suspect a cause creating multiple issues, check out the most common causes below. 

Start with the WeldHelp Issue and Cause Matrix to help find solutions to common welding issues. Save the interactive .pdf file to your computer or print it out to use as a quick reference. 


Common Causes of Resistance Spot Welding Defects


Weld Control/PLC Programming

Equipment Selection

Human Error and Project Set-Up Error

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