Issue/Cause Matrix

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Weld Issues

Possible   Causes

1) Weld current low

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2) Weld current high

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3) Weld force low

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4) Weld force high

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5) Weld time short

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6) Weld time long

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7) Squeeze time short

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8) Hold time short

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9) Hold time long

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10) Wrong tips

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11) Inadequate electrode alignment

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12) Electrode wear

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13) Electrode skidding/sliding

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14) Incorrect electrode dressing

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15) Wrong shank

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16) Insufficient cooling

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17) Poor mechanical connection

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18) Defective air or hydraulic system

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19) Incorrect cylinder

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20) Incorrect hoses

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21) Poor electrical connections

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22) Wrong transformer

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23) Wrong cables/shunts

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24) Poor weld accessibility

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25) Shunting of guns or parts

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26) Incorrect material/coating

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27) Dirty material

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28) Excessive sealer

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29) Poor or varying part fit-up

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30) Damaged part

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31) Weld flange too small

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32) Welds wrongly located

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33) Electrode faces not parallel to workpiece

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34) Inadequate or no gun equalization

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35) Incorrect test procedure

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36) Incorrect workpiece selected

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37) Poor electrode follow-up

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