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Sometimes, going back to the basics can make the difference between a quality repair and a failed repair. When it comes to spot welding, it is important to know what tips to use to get the correct or most effective weld.
Different spot welding tips have an effect on the quality of the weld. Different shapes of electrode tips distribute current, and subsequently heat, in a unique and specific way. Most spot weld tips are flat or dome shaped, with multiple variances of each. This is why it is important to perform test welds with different electrode tips to ensure a proper penetration, especially when it comes to welding with multiple layers.
Some vehicle makers require specific spot welding tips for repairing their vehicles. Tip requirements are usually consistent across different models within an OEM. However, it is always important to check the vehicle-specific repair manual for the required tips.
If the proper tip is not used when spot welding, the following can occur:
- Too much heat
- Too little heat
- Welds that are too big
- Welds that are too small
Too much heat which may weaken the metal, especially high-strength steel (HSS) and ultra-high-strength steel (UHSS). Too little heat may not allow for a deep enough penetration, and the wrong size welds may lead to a repair that is not consistent with the OEM repair procedure. These could all lead to a failed repair.
Always follow OEM procedures and welding specifications to help ensure a complete, safe, and quality repair.
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Article validated in 2025