Welding issues

Cold weld (false 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. Why … 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

Liquid metal embrittlement

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

Electrode degradation

Electrode degradation is one of the common problems in the welding industry. It decreases the nugget size due to reduced current density at the weld interface and reduced conductivity of the electrode tip. 1. Mechanisms of electrode degradation High current and pressure are key characteristics in the resistance welding process. Though they are necessary to … Continue reading