Steel Spot And Plug Weld Nugget Size: Hyundai - 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 Hyundai has to say.

Hyundai provides their welding requirements in one central location in the body repair manuals (BRMs) under: Body Repair ➤ Body Panel Repair Procedure ➤ General Information. This page is broken down into numerous areas. There are specific areas that highlight spot welding and GMA plug welding.

Spot Welding

Hyundai does not indicate a specific spot weld nugget size in their collision repair information.

Hyundai states in the vehicle-specific BRMs under Body Repair ➤ Body Panel Repair Procedure ➤ General Information ➤ Determining A Welding Method category: "It is extremely important that appropriate welding methods, which don't reduce the original strength and durability of the body be used when making repairs, try to use either spot welding or carbon arc (plug) welding. Do not braze any body components other than the ones brazed at the factory"

Some key spot welding instructions from Hyundai:

• When possible spot welds should be done between existing spot welded points.
• Do not spot weld where it is thicker than 3 mm.
• When spot welding, increase the number of spot welds by 30% (1.3 times the original number of welds).

Hyundai Spot Welding Requirement/Recommendation

Per the Hyundai Determining a Welding Method chart, spot welding is: "the most reliable welding method (provides high efficiency and quality of assembled part)."

Plug Welding

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

Hyundai body repair manuals state in the Determining a Welding Method category: "It is extremely important that appropriate welding methods, which don't reduce the original strength and durability of the body be used when making repairs, try to use either spot welding or MIG plug welding."

Hyundai provides a chart that determines what diameter plug weld hole is needed, depending on panel thickness.

Hyundai states the following about the use of GMA plug welds:

• "Use when spot welding can’t be done or spot welding is not necessary."
• "Do not exceed 1 mm of space between parts A tolerance greater than 1 mm will reduce the strength of the welded area."
• "Use the same number of welds as the number of factory welds."
• "Material is thicker than 3 mm."

It is important to note that whether using spot welds or GMA plug welds, Hyundai specifies to: "Do a test welding on a piece of material of the same type and thickness as the part to be welded and proceed if the test welding is good."

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 Hyundai information, check out the Hyundai OEM Information page.

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

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

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Article validated in 2023