Steel Spot And Plug Weld Nugget Size: FCA/Stellantis - UPDATE

Did you know that some OEMs specify nugget size for spot and plug welds? This information is typically found within vehicle-specific repair procedures or can be found under general welding guidelines. Let’s see what FCA/Stellantis has to say.

FCA/Stellantis spot and plug welding information can be found in the Welding and Weld Bonding and Sectioning Locations and Procedures documents in vehicle-specific body repair manuals (BRMs) ➤ Collision Information ➤ Standard Procedures.

Spot Welding

The Welding and Weld Bonding document provides a Minimum Weld Nugget Requirement Chart within vehicle-specific BRMs. This chart provides the governing metal thickness (GMT) and the minimum weld nugget diameter to help ensure a solid weld.

Spot Welding Requirement/Recommendation

Per the FCA/Stellantis vehicle-specific Welding and Weld Bonding document: "The FCA US LLC recommendation is to replace any suspected adhesive with a two-component, corrosion inhibiting structural adhesive when any repairs are made, providing the STRSW process is applicable."

Per the FCA/Stellantis vehicle-specific Sectioning Locations and Procedures document: "All other welds along the sectioned portion of the component must be replaced. Squeeze Type Resistance Spot Welding (STRSW) is the method to be used."

Plug Welding

The Welding and Weld Bonding document provides a Minimum Weld Nugget Requirement Chart within vehicle-specific BRMs. This chart provides the governing metal thickness (GMT) and the minimum weld nugget diameter to help ensure a solid weld.

Per the FCA/Stellantis vehicle-specific Welding and Weld Bonding document: "Number, size and location of welds should closely duplicate the original assembly. Do not place the new spot weld directly on the original spot weld location. Placement of a new weld over an original weld location may lead to metal fatigue or poor weld quality."

Per the FCA/Stellantis vehicle-specific Sectioning Locations and Procedures document: "If accessibility prevents application of spotwelds, MIG plug welds are to be used. Welding of structural panels through 3 or more tiers of panel stack ups will require 9.5 mm plug welds. Exterior panels should be installed using 8 mm plug welds."

Where the spot weld and plug weld nugget size was not identified, refer to the Steel Spot And Plug Weld Nugget Size: UPDATE article. This article provides general guidelines.

Follow OEM welding requirements, including what nugget size is required, to help ensure a complete, safe, and quality repair.

For additional FCA/Stellantis information, check out the following pages:
Alfa Romeo OEM Information
Chrysler OEM Information
Dodge OEM Information
Fiat OEM Information
Jeep OEM Information
RAM OEM Information

Additional I-CAR Collision Repair News you may find helpful:
Back-To-Basics: Destructive Weld Testing
Collision Information Website Access: FCA/Stellantis
Dressing GMA Welds
Steel Spot And Plug Weld Nugget Size: UPDATE
Step-By-Step: Accessing FCA/Stellantis Repair Information
Weld-Through Primer Guidelines: FCA/Stellantis - UPDATE
Welding And MIG Brazing Hotspot

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