Expulsion at Weld Interface

• Short Squeeze Time
• Low Weld Force
• Dirty – Scaly Material
• Poor Fit Up
• Insufficient Edge Distance

Surface Expulsion/Electrode Sticking

• Short Squeeze Time
• Long Weld Time
• Short Hold Time
• Low Weld Force
• High Weld Current
• Dirty - Scaly Material

Electrode Mushrooming

• Insufficient Cooling
• Low weld Force
• High Weld Current
• Small Electrode Face Area
• Long Weld Time
• Welder Head Impacts Work

Low Weld Strength

• Short Weld Time
• Low Weld Force
• Low Weld Current
• Small Electrode Face Area
• Poor Heat Balance
• Welds Too Close Together

Excessive Weld Indentation

• Long Weld Time
• High Weld Force
• High Weld Current
• Poor Fit Up
• Welder Head Impacts Work

Internal Cracks in Weld Nugget

• Short Hold Time
• Low Weld Force
• Dirty- Scaly Material
• Metallurgy of Material Welded
• Poor Head Follow Up

Displaced Weld Nugget

• Electrode Misalignment
• Poor Heat Balance
• Poor Fit UP

Cracks in Parent Material

• High Weld Force
• Insufficient Cooling
• Metallurgy of Material Welded