TechnicianVision · Knowledge base
Steel Spot And Plug Weld Nugget Size: UPDATE
I-CAR · April 6, 2022 · Audi, BMW, Mini, FCA, Stellantis, Ford, Lincoln, General Motors, Honda, Acura, Hyundai, Kia, Mazda, Mercedes-Benz, Mitsubishi, Nissan, INFINITI, Rivian, Rolls-Royce, Subaru, Tesla, Toyota, Lexus, Volkswagen
Summary
This article outlines OEM and general guidelines for steel spot and plug weld nugget sizes, highlighting that nugget measurements can differ before and after destructive testing. It provides general recommendations for spot weld nugget sizes, plug weld bead heights, and plug weld hole diameters when specific OEM guidelines are unavailable.
What to do on the job
Always perform a destructive weld test to confirm proper weld strength and nugget size, adhering to OEM-specific dimensions or general guidelines (such as a spot weld nugget size of five times the thickness of one workpiece) when OEM specs are not provided.
How to use it
Use this document to justify the necessity of performing destructive weld testing and to support billing for proper weld preparation, such as drilling specific plug weld hole sizes (e.g., 8 mm) and achieving correct weld nugget diameters during structural steel repairs.
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