Professional Documents
Culture Documents
Design Guidelines - Spot Welding Chapter
Design Guidelines - Spot Welding Chapter
Chapter 13 - Design
Considerations for Spot Welding
Spot welding is often selected for joining sheet
metal fabrications, stampings and assemblies
because it is fast, reliable and economical. However,
numerous design considerations can affect the
quality and cost of the weld, among them: size of
the spot weld, accessibility, positioning, materials
and thicknesses being joined, and the number of
spots needed to attain the desired strength.
Weldability of Materials
http://www.makeitmetal.com/resources/ch13_spweld.htm 3/11
22/01/2018 Design Guidelines - Spot Welding Chapter
http://www.makeitmetal.com/resources/ch13_spweld.htm 4/11
22/01/2018 Design Guidelines - Spot Welding Chapter
Figure 2. Recommended minimum spacing between spot welds and edges of parts to
be joined also applies to slots and holes in the workpieces.
Figure 3. Improper weld. Excess metal has been expelled from the weld causing the
weld to deform due to excessive indentation and surface cracks.
Figure 4. Existence of deep pits is cause for rejection, as are cracks and burned
metal in the weld.
http://www.makeitmetal.com/resources/ch13_spweld.htm 5/11
22/01/2018 Design Guidelines - Spot Welding Chapter
Figure 5. Excessive edge bulge, which caused weld and base metal to crack, leads
to a rejectable weld.
Figure 7. Specifying spot welds on short flanges could make access nearly
impossible.
http://www.makeitmetal.com/resources/ch13_spweld.htm 6/11
22/01/2018 Design Guidelines - Spot Welding Chapter
Cosmetics
Figure 8. Half shear or extruded button, with their mating holes, can accurately
align components for spot welds where tolerances are important.
http://www.makeitmetal.com/resources/ch13_spweld.htm 8/11
22/01/2018 Design Guidelines - Spot Welding Chapter
Projection Welding
http://www.makeitmetal.com/resources/ch13_spweld.htm 9/11
22/01/2018 Design Guidelines - Spot Welding Chapter
Tolerance Considerations
English Units
.X ± 0.100 (2.54 mm)
.XX ± 0.020 (0.5l mm) (dedicated
tools)
.XX ± 0.030 (0.76 mm) (universal
tools)
.XXX ± 0.010 (0.25 mm)
Figure 11. Recommended method for specifying spot welds and projection welds.
http://www.makeitmetal.com/resources/ch13_spweld.htm 10/11
22/01/2018 Design Guidelines - Spot Welding Chapter
Excerpt taken from Design Guidelines for Metal Stampings and Fabrications -- 2nd
Edition copyright © 1995 Precision Metalforming Association
http://www.makeitmetal.com/resources/ch13_spweld.htm 11/11