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Poor Electrode Follow-upDefinition
The electrode tips do not move towards each other quickly enough during the forging phase of the weld sequence.
Description
During...Read More
Incorrect Workpiece SelectedDefinition
A workpiece that does not conform to the relevant bill of material, blueprint, specifications, etc.
Description
The following are examples...Read More
Incorrect Test ProcedureDefinition
Not following the specified test procedure for determining the characteristics of a resistance weld.
Description
The following are...Read More
Inadequate or No Gun EqualizationDefinition
The welder is not able to close on the workpiece with approximately equal force on each tip.
Description
An equalizing system compensates...Read More
Weld Wrongly LocatedDefinition
The weld has been placed in the wrong location on the part, or has been omitted completely.
Description
Assembly weld locations do not...Read More
Weld Flange Too SmallDefinition
The width of the weld flange is inadequate to allow proper placement of the weld.
Description
Weld flange widths are subject to company...Read More
Damaged PartDefinition
The weld is not correctly made due to the use of a flawed workpiece.
Description
The weld is not properly made due to the workpiece not...Read More
Poor or Varying Part Fit-upDefinition
Fit-up is defined as a measure of the closeness or degree of contact between mating parts.
Description
The metal being welded does not...Read More
Excessive SealerDefinition
Too much sealer or adhesive is applied, or it is applied in the wrong location, such that weld quality is affected.
Description
Although...Read More
Dirty MaterialDefinition
A workpiece surface that is not free of substances that will degrade the welding operation.
Description
Dirty material or surface...Read More
Incorrect Material/CoatingDefinition
The material to be welded has a different base chemistry, processing, or coating than that specified for the part.
Description
The metal...Read More
Shunting of Guns or PartsDefinition
The phenomenon of the secondary current bypasses the nugget being formed is called shunting.
Description
Since shunting always reduces the...Read More
Poor Weld AccessibilityDefinition
Poor weld accessibility is inadequate gun access to the proper weld spot location on the part or welded flange, touching only at the...Read More
Wrong Cables/ShuntsDefinition
The weld is not correctly made due to the use of an incorrect cable or shunt.
Description
Cross Sectional Area:
Too...Read More
Wrong TransformerDefinition
The weld is not correctly made due to the use of an improper transformer.
Description
Transformer size is defined by both the secondary...Read More
Poor Electrical ConnectionsDefinition
Poor electrical connections are the joints, in either the high or low voltage side of the welding circuit that are not properly...Read More
Incorrect HosesDefinition
Hoses do not allow proper flow, pressure, or range of motion.
Description
Hoses provide the fluid (air, oil, water, etc.) flow path for...Read More
Incorrect CylinderDefinition
The weld cylinder will not provide the proper range of electrode force or motion.
Description
The weld cylinder serves two primary...Read More
Poor Mechanical ConnectionDefinition
Weld system components are loose due to wear or improperly applied fasteners.
Description
Correct replacement parts and procedures should...Read More
Insufficient CoolingDefinition
The coolant flow rate is below, or temperature is above, the nameplate rating for the resistance welding component.
Description
The...Read More
Wrong ShankDefinition
A shank of the wrong geometry and/or alloy.
Description
Shank: The current carrying electrode tip holder used when the tip is not inserted...Read More
Incorrect Electrode DressingDefinition
Electrode dressing is a manual or automated operation to reshape electrodes or resurface their uneven faces after they have become...Read More
Electrode Skidding/SlidingDefinition
When the electrodes touch the sheet metal, they may move a short distance along the metal surface. This is called...Read More
Electrode WearDefinition
Electrode wear is a deformation of the tip face over time due to the resistance welding process. Same as: mushrooming, or...Read More
Inadequate Electrode AlignmentDefinition
In welding position, improper electrode alignment exists when either of the two conditions is true:
The contact surfaces of the upper and...Read More
Wrong TipsDefinition
One or both of the electrode tips installed is not of the design or material intended for the application. Same as: wrong caps, improper...Read More
Hold Time LongDefinition
Hold time is the amount of time programmed into the weld controller, typically between the end of weld time and the command to open the...Read More
Hold Time ShortDefinition
Hold time is the period of time programmed into the weld controller, typically between the end of weld time and the command to open the...Read More
Squeeze Time ShortDefinition
Squeeze time is the period of time programmed into the weld controller, typically between the command to close the electrode and the...Read More
Weld Time LongDefinition
For a typical weld, weld time is the amount of time welding current flows through the metal. Weld time is long when it exceeds applicable...Read More
Weld Time ShortDefinition
For a typical weld, weld time is the amount of time welding current flows through the metal. Weld time short is when weld current is...Read More
Weld Force HighDefinition
The interfacial welding force is more than that required by the applicable specification.
Description
Weld force brings the metal between...Read More
Weld Force LowDefinition
The interfacial welding force is less than that required by the applicable specification.
Description
Weld force brings the metal between...Read More
Weld Current HighDefinition
The current passed through during the weld and time is too long for the welding conditions.
Same as: over-current condition, hot...Read More
Weld Current LowDefinition
The applied weld current is insufficient at the existing conditions to form an acceptable weld. Same as: low heat, cold...Read More
