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This table provides recommended spot welding parameters for galvanized low-carbon steel
— zinc-coated sheet stock where the commercial coating weight is 1.25 oz. per square foot.
Parameters include electrode selection, force, current, weld time, nugget size, and minimum
spacing and overlap dimensions. See notes below for material and electrode specifications.
| Material Thickness (Inches)notes 1, 2, & 3 |
 Electrode Diameter & Shapenote 4 |
Net Electrode Force | Welding Current (Approx.) | Weld Time |  Weld Nugget Size (Dw) |
Min. Tensile‑Shear Strength | Min. Weld Spacing | Min. Contacting Overlap | |
|---|---|---|---|---|---|---|---|---|---|
| D (face) In. |
d (shank) In. |
Lb. | Amps. | Cycles | In. | Lb. | Inches | Inches | |
| 0.022 | 5/8 | 3/16 | 300 | 13,000 | 8 | 0.15 | 550 | 5/8 | 5/8 |
| 0.030 | 5/8 | 3/16 | 400 | 13,000 | 10 | 0.16 | 1,000 | 5/8 | 5/8 |
| 0.036 | 5/8 | 1/4 | 500 | 13,500 | 12 | 0.19 | 1,180 | 3/4 | 5/8 |
| 0.039 | 5/8 | 1/4 | 650 | 14,000 | 13 | 0.21 | 1,400 | 3/4 | 5/8 |
| 0.052 | 5/8 | 1/4 | 725 | 14,500 | 18 | 0.22 | 1,700 | 7/8 | 11/16 |
| 0.063 | 3/4 | 1/4 | 850 | 15,500 | 22 | 0.24 | 2,500 | 1‑1/8 | 3/4 |
| 0.078 | 3/4 | 5/16 | 1,200 | 19,000 | 24 | 0.28 | 3,200 | 1‑1/4 | 7/8 |
| 0.093 | 3/4 | 3/8 | 1,400 | 21,000 | 30 | 0.34 | 4,200 | 1‑1/2 | 1 |
| 0.108 | 7/8 | 3/8 | 1,750 | 20,000 | 37 | 0.40 | 5,900 | 1‑3/4 | 1‑1/8 |
| 0.123 | 7/8 | 3/8 | 2,000 | 20,000 | 42 | 0.48 | 7,200 | 2 | 1‑1/8 |
Notes
Note numbers match the original source document.
- Material must be free from dirt, grease, paint, etc. prior to welding, but may have light oil.
- Two equal metal thicknesses of each gage.
- Commercial coating weight is 1.25 oz. per square foot.
- Electrode Material: RWMA Group A, Class 2.
- CMW# 3.
- Water Cooling: 2 gallons per minute.
Projections should be larger in diameter for galvanized than for uncoated material.
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