Welding Problems and Solutions

Resistance welding is a widely used technique in the manufacturing industry, but it still has challenges. Many have encountered complex welding problems that are difficult to solve because it is hard to find the root causes. Since the resistance welding process is very dynamic, the reasons can be complex.

Here we share the common resistance welding problems with possible root causes and solutions.

Cold weld (false weld)

Cold weld (false weld) means no proper weld nugget formed during the resistance welding process.  It is one of the ...

Weld splash

Weld splash (expulsion/spatter) happens when molten material comes out from the weld nugget. It causes cosmetic problems, defective welds, safety ...
spot welding of two steels sheets with Zinc coating shows high risk of crack at the lower sheet.

Liquid metal embrittlement

Liquid metal embrittlement(LME) is a phenomenon where certain metals like Al and steels undergo brittle failure when stressed in contact ...
comparison of used and new electrode. The used electrode has increased tip diameter.

Electrode degradation

Electrode degradation is one of the common problems in the welding industry. It decreases the nugget size due to reduced ...

Welding case studies with SORPAS®

Due to the lack of effective tools to reveal the inside of the weld zone during the rapid and highly dynamic welding process, a practical but tedious way to detect welding problems is by trial and error with many physical weld tests. Simulations can reduce the number of tests and help you to understand the process. For example, it is possible to reveal the inside of the welds and evaluate the welding results by simulations to predict the weld nugget sizes and weld strengths. It is also possible to optimize the welding process settings before launching the welding production.

Check common issues and problems during the welding lifecycle on the following pages. We will present how to use the simulations and optimizations to make good weld designs, achieve stable welding productions, and produce high-quality welds.

Diagram shows how simulation could be applied to each stage of welding processes