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
- Weld Current Low
- Weld Current High
- Weld Force Low
- Weld Force High
- Weld Time Short
- Weld Time Long
- Squeeze Time Short
- Hold Time Short
- Hold Time Long
- Poor Tip Follow-Up
Equipment Selection
- Wrong Transformer
- Wrong Cables or Shunts
- Incorrect Cylinder
- Incorrect Hoses
- Wrong Electrodes (Tips)
- Incorrect Tip Dressing
- Wrong Shank
- Malfunctioning or Incorrect Air or Hydraulics
- Poor Mechanical Connections
- Poor Electrical Connection
Human Error and Project Set-Up Error
- Electrode Wear
- Incorrect Electrode Alignment
- Electrode Faces Not Parallel
- Electrode Skidding or Sliding
- Dirty Welding Materials
- Excessive Sealer
- Poor Part Fit-Up
- Poor Weld Access
- Shunting of Guns or Parts
- Incorrect Materials or Coatings
- Damaged Part
- Weld Flange Small
- Welds Mislocated
- Inadequate or No Gun Equalization
- Incorrect Tests
- Incorrect Workpiece
- Insufficient Cooling
