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Applications include attachment of reinforcing braces and stiffeners, functional brackets, hinges and other parts. Often, spot welding is the method of choice for assembly of entire enclosures, cabinets and multipart assemblies. Thickness of the majority of parts joined by spot welding ranges up to 1/8 in. (3 mm) for each member, although parts up to 1/4 in. (6 mm) thick have been successfully spot welded. Based on the experience of stampers and fabricators, certain general recommendations can facilitate spot welding of a sheet metal design, no matter what metalforming process is used to make it. It is always useful to consult with the metalformer in the design stage when questions arise regarding the part design, application of spot welding or, control of spot welding cost for a particular design.

One alternative to plug welding is “MIG spot welding”. It is similar to plug welding, although a hole is not drilled in the front sheet of metal. Instead the power of the MIG is relied upon to fully melt the top sheet and penetrate into the back sheet. This technique would require less preparation work than plug welding, but the two sheets need to be in tight contact and high amps used to complete the weld or else the weld could be very weak. Plug welding is a much more suitable technique for all but the most experienced welders.

How Does Spot Welding Work? A form of resistance welding, spot welding is one of the oldest welding processes whereby two or more sheets of metal are welded together without the use of any filler material. The process involves applying pressure and heat to the weld area using shaped alloy copper electrodes which convey an electrical current through the weld pieces. The material melts, fusing the parts together at which point the current is turned off, pressure from the electrodes is maintained and the molten “nugget” solidifies to form the joint. Read more details on Tecna Spot Welder.

Spot welding machines represent a significant long-term investment that can decline in value. Their high performance has led to widespread use in automotive manufacturing; their use can be automated by combining them with extremely fast, precise robots. Radiators can be welded by the same process except using rollers to obtain a continuous, watertight weld. Industrially made furniture and other functional metal objects such as lampshade frames are also spot-welded. The process gives an impressive quality of weld without deforming the components it is used on.