This document discusses plug welds, which are used to replace factory spot welds. A plug weld is formed by punching or drilling a 5/16" hole in the outer panel to be joined, duplicating the number and location of original spot welds. The document provides instructions on how to prepare samples, techniques for performing plug welds, how to inspect plug welds using an I-CAR gauge, and how to perform a destructive test to ensure proper penetration. Plug welds are commonly used with other welds like butt welds and are an important technique for automotive collision repair.
This document discusses plug welds, which are used to replace factory spot welds. A plug weld is formed by punching or drilling a 5/16" hole in the outer panel to be joined, duplicating the number and location of original spot welds. The document provides instructions on how to prepare samples, techniques for performing plug welds, how to inspect plug welds using an I-CAR gauge, and how to perform a destructive test to ensure proper penetration. Plug welds are commonly used with other welds like butt welds and are an important technique for automotive collision repair.
This document discusses plug welds, which are used to replace factory spot welds. A plug weld is formed by punching or drilling a 5/16" hole in the outer panel to be joined, duplicating the number and location of original spot welds. The document provides instructions on how to prepare samples, techniques for performing plug welds, how to inspect plug welds using an I-CAR gauge, and how to perform a destructive test to ensure proper penetration. Plug welds are commonly used with other welds like butt welds and are an important technique for automotive collision repair.
This document discusses plug welds, which are used to replace factory spot welds. A plug weld is formed by punching or drilling a 5/16" hole in the outer panel to be joined, duplicating the number and location of original spot welds. The document provides instructions on how to prepare samples, techniques for performing plug welds, how to inspect plug welds using an I-CAR gauge, and how to perform a destructive test to ensure proper penetration. Plug welds are commonly used with other welds like butt welds and are an important technique for automotive collision repair.
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Weld Types - Plug Weld
Plug Weld Plug welds are used to replace factory spot welds. The plug weld is formed by punching or drilling a 5/16 hole in the outer panel to be joined. Duplicate the number and location of the original factory spot welds. UVU CRT 2009
Plug Welds on Rail
Plug Welds are commonly used with other weld types such as the butt with backing as shown in this picture. UVU CRT 2009
Plug Weld With the example given you should have a basic understanding of what a plug weld is and where it is used. Print off the Plug Weld- Task Performance Sheet The next step is to tune the welder and perform a Plug Weld that will be evaluated visually and destructively. UVU CRT 2009
Preparing to Weld Select two 3x5 coupons. Punch a series of holes with the 5/16 metal punch. Place this coupon on top of the other.
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Plug Weld Techniques
Two Recommended Techniques
Start in center of hole
and move around the edge.
Start circling on the
edge and finish in the center
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Practice Practice both techniques to find your preferred method. When you have a good weld move on to the next assignment.
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Assignment Using two 3x5 coupons punch a 5/16 hole in one corner. Position this coupon over the other as shown. UVU CRT 2009
Weld With your preferred technique make a plug weld that completely fills the hole. This weld will be visually inspected and destructively tested.
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Plug Weld A Good Weld
Should completely fill the hole. Have a dimple in the center of the weld. Have a penetration ripple on the back of the panel. UVU CRT 2009
Using I-Cars WQT Gauge
I-Car has provided a gauge to help in visually inspecting the welds for:
bead length width height penetration defects
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Using I-Cars WQT Gauge
Check the Minimum and Maximum Diameter.
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I-Car MIG Welding Gauge
Next check the bead height.
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Record the Results
After the visual inspection is complete record the results on the task performance sheet and have the instructor verify your results. Now the destructive test will need to be performed.
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Destructive Weld Test
Secure bottom coupon in vise. Bend top piece back and forth to separate coupons. A hole should remain in the bottom coupon. UVU CRT 2009
Final Weld Series
When the welds pass the visual and destructive test observe the final voltage and wire speed setting. Mark the destructive test results on the task performance sheet. Complete your final plug weld series in the flat vertical and overhead position. Turn these in for final grading. UVU CRT 2009
References Miller Electric Mfg. Co. Education. http://www.millerwelds.com/education/library.html, 2006. Lincoln Electric Co. Lincoln Welders. http://www.lincolnelectric.com/, 2006. Inter Industry Conference on Automotive Collision Repair. I-CAR Online Training. http://www.i-car.com/, 2006.
