Replacing a resistance spot weld with a plug weld.

[franklineng]

What is the best way of determining the proper size of a plug weld to replace a resistance weld in an assembly? Is it based upon the diameter of the spot weld electrode and the depth of the plug weld.

 

[CWIC]

What type of material(s) and thickness(es) is your application?

Plug weld sizes are detrmined by the diameter of the weld in the plane of the faying surfaces.

 

[franklineng]

The part is 11 guage 0.120 in ASTM A606 material.

 

[CWIC]

What welding process do you intend to use for the plug welds?

 

[gdodd]

A plug weld with satisfactory penetration and equal or greater weld area will be as strong as a spot weld.