How to Spot Weld

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Spot welding uses the heat from an electrical current to join 2 pieces of metal quickly, and is typically used for joining sheet metal. It’s also easy to do with a spot welding machine, which has 2 electrode tongs about 6 inches (15 cm) long that pass an electrical current through the metal to fuse them together. We'll walk you through the spot welding process in a step-by-step welding tutorial.

Part 1
Part 1 of 2:

Connecting the Metal Pieces

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    Debris from previous welds can affect the quality of your spot weld. If there’s any dust or dirt on the metal you plan to weld or the electrodes, they could spark up when you weld the metal. Take a clean cloth and wipe down the area of the metal you plan to weld as well as the tips of the electrode tongs. [1]
    • Use a clean cloth so you don’t get any more dirt or dust on the surface.
    • You don’t need to use soap or water to clean the area.
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    Connect the pieces of metal that you plan to weld so they’re flush against each other. Take a pair of vice grips and clamp down on the metal so they don’t move and you have a handle to hold them with. [2]
    • Vice grip pliers allow you to clamp down and lock the pliers so they stay tight.
    • You can find vice grip pliers at hardware stores and online.
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    The 2 electrodes of the spot welding machine are adjustable. Use the adjustment knob or wheel to spread them out so they’re wide enough for you to fit the metal that you plan to weld between them. [3]

    Tip: Give a little bit of extra room so you can fit the metal between the tongs. You’ll tighten them so they’re touching the metal when you spot weld.

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Part 2
Part 2 of 2:

Fusing the Metal Together

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    Spot welding creates bright light and lots of heat, but there aren’t any sparks, so you don’t need to wear a full welding mask. To keep your eyes and hands protected, be sure to put on a pair of well-fitting welding gloves and welding goggles, which will block the bright light from damaging your eyes. [4]
    • Adjust the googles so they fit on your face securely.
    • You can find welding gloves and goggles at hardware stores and online.
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    When you’re ready to weld, double-check that the machine is plugged into a wall outlet nearby. Then, flip the power switch so the welder is turned on and ready to go.
    • Don’t turn on the machine until you’re ready to spot weld.
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    Hold the handle of the vice grip pliers and move the metal between the 2 tongs. Keep the metal still as you ready the tongs to spot weld and fuse them together. [5]
    • Use 1 hand to hold the metal so you can use the other to press down the handle.
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    Squeeze the handle on the machine to close the tongs. When they connect with the metal, the 2 ends of the electrodes will pass a current through the metal to heat up the spot where they connect. [6]
    • You’ll see the metal start to heat up after a few seconds.
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    To create a proper weld that will last, allow the electrode tongs to remain connected to the metal for at least 3 seconds. Hold the handle down to keep the electrodes connected. [7]
    • Don’t hold the handle for more than 5 seconds or you could overheat the metal and it may melt too much to create a clean weld.

    Tip: If 1 burst of welding isn’t enough, place the metal back between the tongs at the same location, and hold the handle down for another 3 seconds.

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    Pull the metal out from between the 2 tongs and inspect it to make sure it’s been fused together well. Let the metal cool before you weld any other spots. [8]
    • Take a clean cloth and give the metal a quick wipe to remove any soot that may be on the surface once the metal has cooled.
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    To add additional welding spots, remove the vice grip pliers and move them over from the spot that you welded. Reclamp them so the pieces of metal are tightly connected and you have a handle to move the metal back between the 2 electrode tongs. [9]
    • Make sure the metal has cooled before you weld any additional spots.
    • Repeat the process as many times as you need to in order to fully connect the metal.
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Expert Q&A

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  • Question
    How do you spot weld properly?
    Jones Welding & Industrial Supply Company
    Industrial Welding Experts
    Welding can be a complex and potentially hazardous activity. The information provided here is meant to serve as a general guideline, but it is crucial to prioritize safety and consult with a qualified welding specialist or instructor if you have any doubts or concerns. Welding techniques, materials, and equipment may vary, and the proper procedures and precautions may depend on specific circumstances. Welding involves inherent risks, such as exposure to high temperatures, intense light, fumes, and electrical hazards. Therefore, it is essential to receive proper training, follow manufacturer's guidelines, and adhere to safety regulations and practices. WikiHow and Jones Welding & Industrial Supply, Inc do not assume any responsibility or liability for any injuries, damages, or losses resulting from the use or misuse of the information provided. Always seek professional advice and take appropriate precautions to ensure your safety when engaging in welding activities. You can always consult with your local welding supply store to be led into the right direction!"
    Jones Welding & Industrial Supply Company
    Industrial Welding Experts
    Expert Answer
    Prepare the workpieces first by ensuring that the metal sheets you intend to spot weld are clean and contaminant-free. Then, adjust the spot welder settings by setting the appropriate time and pressure settings based on the material thickness and type. From there, place the electrodes on either side of the workpieces, ensuring that they make good contact with the metal surfaces. Once you've done this, activate the spot welder to initiate the welding process.
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      Warnings

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      Things You’ll Need

      • Spot welder
      • Vice grip pliers
      • Clean cloth
      • Welding gloves
      • Welding goggles

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      Expert Interview

      Thanks for reading our article! If you’d like to learn more about metalworking, check out our in-depth interview with Jones Welding & Industrial Supply Company .

      References

      1. ↑ https://www.mechanicwiz.com/spot-welding/
      2. ↑ https://youtu.be/ogyBd0CWbS8?t=163
      3. ↑ https://youtu.be/nhSuXM5RnvI?t=35
      4. ↑ https://youtu.be/nhSuXM5RnvI?t=28
      5. ↑ https://www.mechanicwiz.com/spot-welding/
      6. ↑ https://sciencing.com/disadvantages-advantages-of-spot-welding-12283375.html
      7. ↑ https://youtu.be/ogyBd0CWbS8?t=226
      8. ↑ https://youtu.be/ogyBd0CWbS8?t=231
      9. ↑ https://youtu.be/ogyBd0CWbS8?t=236

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