Steel Spot And Plug Weld Nugget Size: Audi - UPDATE

Did you know that many 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 Audi has to say.

Spot Welding

Audi spot welding specifications can be found in the Body Repair, Body Collision Repair manual under the Resistance Spot Welding category.

Per the Body Repair, Body Collision Repair manual: "The basic principle for repair welding is to re-create as much of the original welded connection as possible." It also requires that: "the resistance spot welder is strong enough to produce weld spot diameters like at the factory." GMA plug welding is used where spot welding arms cannot reach.

The manual has a formula for calculating the correct spot weld nugget diameter based on the thickness of the panels being welded. Audi states that test panels should be used before repairing the vehicle and to: "check all spot weld connections 100% with a chisel test."

Audi Spot Welding Requirement/Recommendation

Per the Body Repair, Collision Repair manual: "On vehicles with ultra-high-strength hot-formed steel, spot welding devices with inverter technology (see workshop equipment and special tools catalog) art to be used."

"Gas-shielded plug welding is mostly used when the standard implemented resistance spots cannot be recreated, for example due to limited accessibility."

Plug Welding

Audi does not indicate a specific plug weld nugget size in their collision repair information.

Plug weld hole diameters can be found in vehicle-specific body repair manuals (BRMs). Repair procedures that use plug welding will specify what diameter drill bit to use for the 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 Audi information, check out the Audi OEM Information page.

Additional I-CAR Collision Repair News you may find helpful:

• Back-To-Basics: Destructive Weld Testing
• Collision Information Website Access: Audi
• Dressing Steel GMA Welds: UPDATE
• Steel Spot And Plug Weld Nugget Size: UPDATE
• Step-By-Step: Accessing Audi Repair Information
• Weld-Through Primer Guidelines: Audi
• Welding And MIG Brazing Hotspot

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