Defect Troubleshooting Guide

Resistance Welding | Quick Reference Chart

ALCAVIL S.A. de C.V.
Phone: +52 81 1636 1511 | ventas1@alcavil.com.mx
alcavil.com.mx | Monterrey, N.L. Mexico
Probable Cause
Remote Possibility
ELECTRODES
CAUSE AREA Expulsion at Interface Surface Expulsion / Sticking Electrode Mushrooming Low Weld Strength Excessive Indentation Internal Crack in Nugget Cracks in Parent Material Blackened Weld Nugget
Electrode face too small
Electrode face too large
Misaligned electrodes
Insufficient cooling
Excessive weld time
PARTS WELDED
CAUSE AREA Expulsion at Interface Surface Expulsion / Sticking Electrode Mushrooming Low Weld Strength Excessive Indentation Internal Crack in Nugget Cracks in Parent Material Blackened Weld Nugget
Dirty / scaled material
Poor part fit-up
Insufficient edge distance
Welds too close together
Material metallurgy
Poor head follow-up
WELDING CONDITIONS
CAUSE AREA Expulsion at Interface Surface Expulsion / Sticking Electrode Mushrooming Low Weld Strength Excessive Indentation Internal Crack in Nugget Cracks in Parent Material Blackened Weld Nugget
Squeeze Time - Too short
Weld Time - Too short
Weld Time - Too long
Hold Time - Too short
Weld Force - Too low
Weld Force - Too high
Weld Current - Too low
Weld Current - Too high