Spot Welding Cheat Sheet

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Setting Tong Gap

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  1. Close tongs and measure space between electrode tip contact surfaces.
  2. Measure the thickness of the total weldment
  3. Adjust tong gap to measurement of step 2, less 1/2 the thickness of the thinnest workpiece to be welded.
  4. Insert the parts to be welded between the electrode tips and bring tips to welding pressure.
    • There should be a slight deflection of the tongs.
    • This may be measured with a straight edge set on the tong longitudinal axis.
  5. Energize the spot welding machine and make a sample weld.
  6. Test the weld by visual and mechanical means. Check the electrode tip for deformation and contamination.
  7. Adjust tong pressure as required.


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