Issue: Non-Round Welds

Welds or weld buttons are not circular.


Non-round welds may be caused in several ways. Typically they are the result of using worn electrode tips, improperly aligned welding equipment, or insufficient weld energy. Reference should be made to appropriate company standards to determine whether any non-round conditions are acceptable.


A non-circular and/or unsmooth electrode impression on the workpiece before teardown may indicate the presence of a non-round weld. Note that non-round welds can also occur under indentations with a perfect appearance.

After teardown, non-round welds would be indicated by the shape of the remaining


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

Maintenance: Recurrent nonround welds may indicate that equipment maintenance is required.

Possible Causes

Strong Possibilities

Weak Possibilities

Note: Also see Mislocated/Edge Welds.

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