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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..

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Weld Types - Plug Weld

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    1. Weld Types - Plug Weld

    2. 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

    3. 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

    4. 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

    5. 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. UVU CRT 2009

    6. Plug Weld Techniques UVU CRT 2009

    7. Practice Practice both techniques to find your preferred method. When you have a good weld move on to the next assignment. UVU CRT 2009

    8. Assignment Using two 3x5 coupons punch a 5/16 hole in one corner. Position this coupon over the other as shown. UVU CRT 2009

    9. Weld With your preferred technique make a plug weld that completely fills the hole. This weld will be visually inspected and destructively tested. UVU CRT 2009

    10. 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

    11. 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 UVU CRT 2009

    12. Using I-Cars WQT Gauge UVU CRT 2009

    13. I-Car MIG Welding Gauge UVU CRT 2009

    14. 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. UVU CRT 2009

    15. 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

    16. 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

    17. 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. UVU CRT 2009

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