Spot Welding Setting Charts
Basic Principles of Spot Welding
| Typical spot welding conditions for uncoated low carbon steel sheets of thickness thickness 0.4 mm to 3.0 mm | ||||||||
| Single sheet thickness | Electrode tip diameter | Welding conditions | ||||||
| Medium force, long time conditions | High force, short time conditions | |||||||
| Over mm | Up to and including mm | Force kN | Weld time 1) cycles | Current kA | Force kN | Weld time 1) cycles | Current kA | |
| 0.4 | 0.6 | 4 | 0.9 to 1.1 | 5 to 7 | 4 to 6 | 1.3 to 1.8 | 4 to 5 | 5 to 8 |
| 0.6 | 0.8 | 4 | 1.2 to 1.3 | 7 to 10 | 5 to 7 | 1.7 to 2 | 6 to 8 | 6 to 9 |
| 0.8 | 1.0 | 5 | 1.4 to 1.5 | 9 to 12 | 6 to 8 | 1.9 to 2.6 | 7 to 10 | 7 to 10 |
| 1.0 | 1.2 | 5 | 1.6 to 1.8 | 11 to 15 | 7 to 9 | 2.5 to 3.2 | 8 to 12 | 8 to 12 |
| 1.2 | 1.6 | 6 | 1.9 to 2.1 | 14 to 18 | 8 to 11 | 3.0 to 4.0 | 9 to 13 | 10 to 13 |
| 1.6 | 2.0 | 7 | 2.6 to 2.9 | 18 to 22 | 9 to 13 | 3.9 to 5.2 | 10 to 14 | 12 to 15 |
| 2.0 | 2.5 | 8 | 3.4 to 3.7 | 22 to 28 | 10 to 15 | 5.0 to 6.2 | 12 to 16 | 14 to 18 |
| 2.5 | 3.0 | 9 | 4.4 to 4.7 | 28 to 35 | 12 to 17 | 6.0 to 7.5 | 15 to 20 | 17 to 20 |
| 1) 1 cycle = 0.02s | ||||||||
| Typical spot welding conditions for uncoated low carbon steel plates of thickness 3.0 mm to 12.0 mm using a single-phase a.c. machine | |||||
| Single plate thickness | Electrode tip diameter
mm |
Welding conditions | |||
| Over mm | Up to and including mm | Force kN | Total pulsed weld time s | Current kA | |
| 3.0 | 4.0 | 12 | 11.5 | 0.70 | 20 |
| 4.0 | 5.0 | 14 | 15.5 | 1.40 | 23 |
| 5.0 | 6.0 | 17 | 22.7 | 2.38 | 28 |
| 6.0 | 7.0 | 18 | 25.5 | 3.08 | 30 |
| 7.0 | 8.0 | 19 | 28.5 | 4.34 | 33 |
| 8.0 | 9.0 | 21 | 34.5 | 5.46 | 36 |
| 9.0 | 10.0 | 23 | 41.5 | 7.56 | 38 |
| 10 | 12.0 | 26 | 53.0 | 11.90 | 43 |
| 1) 1 cycle = 0.02s | |||||
Note 1. Multiple impulses of 0.1s (5 cycles) on 0.04 s (2 cycles) off, are recommended Note 2. Total pulsed weld time is (on time plus off) multiplied by number of pulses. |
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| Typical spot welding conditions for hot-dip zinc, zinc-5 % aluminium, zinc-55 % aluminium and electrolytically deposited zinc coated steel sheets of combined thickness 0.4 mm to 3.0 mm | ||||||||
| Single sheet thickness | Electrode tip diameter | Welding conditions | ||||||
| Hot-dip zinc, zinc-5 % aluminium, zinc-55 % aluminium (see note 1) | Electrolytically deposited zinc (See note 2) | |||||||
| Over mm | Up to and including mm | Force kN | Weld time 1) cycles | Current kA | Force kN | Weld time 1) cycles | Current kA | |
| 0.4 | 0.6 | 4 | 1.5 to 2.0 | 6 to 8 | 7 to 9 | 1.5 to 2.0 | 6 to 7 | 6.5 to 8.5 |
| 0.6 | 0.8 | 4 | 1.9 to 2.2 | 8 to 10 | 8 to 10 | 1.9 to 2.2 | 8 to 10 | 7.5 to 9.5 |
| 0.8 | 1.0 | 5 | 2.2 to 2.9 | 9 to 12 | 9 to 11 | 2.2 to 2.9 | 9 to 12 | 8.5 to 10.0 |
| 1.0 | 1.2 | 5 | 2.9 to 3.6 | 10 to 13 | 10 to 13 | 2.8 to 3.6 | 10 to 13 | 9.5 to 12.5 |
| 1.2 | 1.6 | 6 | 3.4 to 4.5 | 11 to 15 | 14 to 16 | 3.4 to 4.5 | 11 to 15 | 12.0 to 14.5 |
| 1.6 | 2.0 | 7 | 4.4 to 5.5 | 12 to 16 | 18.0 to 21.0 | 4.4 to 5.5 | 12 to 16 | 14.0 to 17.0 |
| 2.0 | 2.5 | 8 | 5.4 to 6.8 | 14 to 18 | 22.0 to 26 | 5.4 to 6.8 | 14 to 18 | 17.0 to 22.0 |
| 2.5 | 3.0 | 9 | 6.6 to 8.0 | 17 to 21 | 26 to 30.0 | 6.6 to 8.0 | 17 to 21 | 19.0 to 24.0 |
| 1) 1 cycle = 0.02s | ||||||||
| Note 1. Applicable for coating thickness G275 ( = 20µ m on each surface) | ||||||||
| Note 2. Applicable for coating thickness 7.5µ m on each surface. | ||||||||
| Typical spot welding of double sided iron-zinc alloy and zinc-nickel alloy coated steels of sheet thickness 0.4 to 3.0 mm | |||||
| Single plate thickness | Electrode
tip diameter
mm |
Welding conditions | |||
| Over mm | Up to and including mm | Force kN | Weld time1) cycles | Current kA | |
| 0.4 | 0.6 | 4 | 1.4 to 1.9 | 4 to 6 | 6.0 to 8.5 |
| 0.6 | 0.8 | 4 | 1.8 to 2.1 | 6 to 8 | 7.0 to 9.5 |
| 0.8 | 1.0 | 5 | 2.1 to 2.8 | 7 to 10 | 8.0 to 10.5 |
| 1.0 | 1.2 | 5 | 2.7 to 3.4 | 8 to 12 | 9.0 to 12.0 |
| 1.2 | 1.6 | 6 | 3.2 to 4.3 | 9 to 13 | 11.0 to 14.0 |
| 1.6 | 2.0 | 7 | 4.2 to 5.3 | 10 to 14 | 13.0 to 16.5 |
| 2.0 | 2.5 | 8 | 5.2 to 6.5 | 12 to 16 | 16.0 to 21.0 |
| 2.5 | 3.0 | 9 | 6.4 to 7.8 | 15 to 20 | 18.0 to 23.0 |
| 1) 1 cycle = 0.02s | |||||
| Note. These conditions are applicable to iron-zinc alloy coatings of thickness, for each surface, of between 5µ m to 10 µ m (equal to a coating mass of 35 to 70 g/m) and zinc-nickel coatings of thickness, for each surface, of up to 7µ m (equal to a coating mass of 50g/m²). | |||||
| Typical spot welding conditions for two terne coated steel sheets of thickness 0.4 mm to 1.6 mm | |||||
| Single plate thickness | Electrode tip diameter
mm |
Welding conditions | |||
| Over mm | Up to and including mm | Force kN | Weld time1) cycles | Current kA | |
| 0.4 | 0.6 | 4 | 1.5 to 2.0 | 6 to 8 | 7 to 9 |
| 0.6 | 0.8 | 4 | 1.9 to 2.2 | 8 to 10 | 8 to 10 |
| 0.8 | 1.0 | 5 | 2.1 to 2.9 | 9 to 12 | 9 to 11 |
| 1.0 | 1.2 | 5 | 2.9 to 3.6 | 10 to 13 | 10 to 13 |
| 1.2 | 1.6 | 6 | 3.4 to 4.5 | 11 to 15 | 14 to 16 |
| 1) 1 cycle = 0.02s | |||||
| Note. These conditions are applicable to terne coated steel of coating mass 150 g/m², including both surfaces | |||||
| Typical spot welding conditions for aluminium coated steel sheet of thickness 0.4 mm to 2.0 mm | |||||
| Single plate thickness | Electrode tip diameter
mm |
Welding conditions | |||
| Over mm | Up to and including mm | Force kN | Weld time 1) cycles | Current kA | |
| 0.4 | 0.6 | 4 | 1.5 to 2.0 | 8 to 10 | 8.5 to 10.0 |
| 0.6 | 0.8 | 4 | 1.9 to 2.2 | 10 to 12 | 9.0 to 11.0 |
| 0.8 | 1.0 | 5 | 2.2 to 2.9 | 12 to 14 | 10.0 to 12.0 |
| 1.0 | 1.2 | 5 | 2.8 to 3.6 | 14 to 16 | 11.5 to 13.0 |
| 1.2 | 1.6 | 6 | 3.4 to 4.5 | 18 to 22 | 12.0 to 15.0 |
| 1.6 | 2.0 | 7 | 4.4 to 5.5 | 22 to 26 | 14.5 to 17.5 |
| 1) 1 cycle = 0.02s | |||||
| Note. These conditions are applicable to terne coated steel of coating mass 150 g/m², including both surfaces | |||||
| Typical minimum weld strength values (shear to failure) for low carbon steel of 280 N/mm² minimum tensile strength. | ||||||||
| Sheet thickness mm | Nominal 3.5t weld size | Nominal 4√t weld size | Nominal 5√t weld size | Nominal 6√t weld size | ||||
| Weld diameter mm | Weld strength kN | Weld diameter mm | Weld strength kN | Weld diameter mm | Weld strength kN | Weld diameter mm | Weld strength kN | |
| 0.6 | 2.7 | 1.3 | 3.1 | 1.6 | 3.9 | 2.0 | 4.6 | 2.3 |
| 0.8 | 3.1 | 2.3 | 3.6 | 3.0 | 4.5 | 3.6 | 5.4 | 4.2 |
| 1.0 | 3.5 | 3.2 | 4.0 | 3.7 | 5.0 | 4.3 | 6.0 | 5.1 |
| 1.2 | 3.8 | 4.1 | 4.4 | 4.6 | 5.5 | 5.4 | 6.6 | 6.2 |
| 1.6 | 4.4 | 5.5 | 5.1 | 6.0 | 6.3 | 7.4 | 7.6 | 8.3 |
| 2.0 | 5.0 | 7.2 | 5.7 | 8.4 | 7.1 | 10.8 | 8.5 | 13.0 |
| 2.5 | 5.5 | 10.6 | 6.3 | 11.8 | 7.9 | 14.5 | 9.5 | 17.3 |
| 3.0 | 6.1 | 12.0 | 6.9 | 14.0 | 8.66 | 17.8 | 10.4 | 22.0 |
