Common welding problems
False weld (cold weld)
Cold weld (false weld) means no proper weld nugget formed during the resistance welding process. It is one of the most common weldability problems in the automotive industry in multi-sheet spot welding with dissimilar materials. Increasing false welds can harm the safety of the cars drastically or the production line must stop and rerun. 2 … Continue reading
Weld splash
Weld splash (expulsion/spatter) happens when molten material comes out from the weld nugget. It causes cosmetic problems, defective welds, safety issues for workers, and maintenance problems in the production line. Weld splash is one of the most common issues in the welding industry. Why does weld splash happen? There are many causes of splashes. The … Continue reading
Gap between sheets
Gap between welding parts can cause unstable welding production. It can lead to early splash or no weld due to bad contact or improper gap closure. This case study shows how the gap size affects the splash limit and the lower limit of process window by using SORPAS simulation.
Liquid metal embrittlement (LME)
Liquid metal embrittlement(LME) is a phenomenon where certain metals like Al and steels undergo brittle failure when stressed in contact with liquid metals like Zn, Sn, Pb, etc. One of the challenges in the welding industry is cracking due to LME observed on spot welds of Zn-coated High Strength Steel. Liquid zinc penetration results in … Continue reading