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Good design practices attempt to limit spot welding on appearance or cosmetic surfaces. While textured paints can be used to hide small electrode marks on finished surfaces, grinding, or filling and grinding, is often required and can double the cost of the welding operation. Often, structural elements such as stiffeners are required to reinforce large cosmetic surfaces. For these applications, designers should select material which is thinner than the material from which the appearance part is fabricated. This assures that weld shrinkage will occur on the noncosmetic part which helps to control the cost of filling and abrasive finishing.

If the sheets are the same thickness then the power setting used for plug welding would be the same as you would use for 1.5 times the thickness of one of the sheets. This is the sort of penetration you would expect from a plug weld. The molten pool is just breaking out of the reverse of the back sheet. The heat marks indicate the weld has arced against the back sheet rather than at the side of the hole. If you don’t get these marks then consider a little seam welding just to be sure. There is a special clamp designed for plug welding that makes life really easy. The parts you see in the photograph are attached to a normal mole grip. This clamp came in a set of three random welding clamps all of which are extremely useful.

The welding heat is generated by the electric current, which is transferred to the workpiece through copper alloy electrodes. Copper is used for the electrodes as it has a high thermal conductivity and low electrical resistance compared to most other metals, ensuring that the heat is generated preferentially in the work pieces rather than the electrodes. The amount of heat depends on the thermal conductivity and electrical resistance of the metal as well as the amount of time the current is applied. Other materials commonly spot welded include stainless steels (in particular austenitic and ferritic grades), nickel alloys and titanium. Read extra details at Tecna Spot Welder Arms.

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.