![]() ![]() ![]() Once the outer edge is secured, you can work in circles towards the centre to complete the weld. Most welders recommend starting by welding around the edge of the hole with the welding gun at an angle to ensure fusion, as with a successful fillet weld. The final stage is to make the plug weld itself, this requires experience and practice to master. It is important to use a plug weld clamp to hold the metals together and stop them moving during the welding process. The size of the holes differs depending on the size of the workpieces being joined, with thicker sheets requiring larger holes but, as an example 7.5mm should be large enough for 0.8 or 1mm sheets. This is commonly done by drilling through the top workpiece. Once you have marked the position of the welds, it is time to make the holes for the plug welds to fill. Next, mark out the position of your plug welds on the uppermost workpiece (which is generally the thicker of the two), making sure to evenly space the welds if you are using more than one. ![]() To avoid any welding defects, it is important to first clean the workpieces. The plug welding process can be broken down into five steps, as follows: 1. National Structural Integrity Research Centre.Structural Integrity Research Foundation. ![]()
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