Transcript Butt Joint with Backing - Utah Valley University

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.
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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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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.
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Preparing to Weld
 Select two 3”x5”
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 3”x5”
coupons punch a
5/16” hole in one
corner.
 Position this
coupon over the
other as shown.
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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.
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Using I-Car’s 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-Car’s 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.
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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.
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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.
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