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Replacing a resistance spot weld with a plug weld.

Replacing a resistance spot weld with a plug weld.

Replacing a resistance spot weld with a plug weld.

(OP)
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.

RE: Replacing a resistance spot weld with a plug weld.

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.   

RE: Replacing a resistance spot weld with a plug weld.

(OP)
The part is 11 guage 0.120 in ASTM A606 material.

RE: Replacing a resistance spot weld with a plug weld.

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

RE: Replacing a resistance spot weld with a plug weld.

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

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