What Is a Plug Weld And How Does It Work?

Plug welding is used to repair broken holes in airframes like fan and exit casings. Instead of destroying the entire assembly, our method allows aerospace businesses to recover these components by repairing each hole.

Larger holes can also be attributed to machine vibrations, which can lead the holes to enlarge over time.

What Is a Plug Weld?

A welder is used to join two metal materials together with a plug weld. A hole is drilled in the top part and it is put over the base one while assembling the components. The two components are then held together using a weld created by passing a bead within the drilled hole.

This form of the weld is commonly utilized while replacing body panels in vehicle body maintenance. Because the end product is round, it resembles a plug weld. When combining two metals of different thicknesses, this plug weld is frequently used. A strong weld may be made by fusing the thin top component to the thicker bottom piece.

Why Are Plug Welds Used?

It's being used to join two flat plates together by drilling one or more slots or holes in the top tipped half and then filling them with filler metal.

Plug welding is used to repair broken holes in aircraft components like compressor and exit casings. Instead of destroying the entire assembly, our method allows aero businesses to recover these components by repairing each hole.

What Is the Difference Between a Spot Weld and a Plug Weld?

Plug welds are far more durable than spot welds. They might be many times more powerful than a resistive type weld created by clipping two parts together if properly done with pure metal pieces. The cleanup of the weld is a disadvantage.

A spot weld is significantly easier and simpler to do, which means less preparation time. If you're planning to use a spot welder, make sure you have good equipment.

Avoid the low-cost hand-held machine equipment. It welds when the iron is fresh, but the welds are readily broken apart. Spot welders of good grade have adequate power to weld inside the coatings and primers. Low-power machines require clean metal that is free of coverings.

Steps that Need to Be Followed

  • Obviously, the very first step is to prepare. So that you don't wind up with either welding error, you'll need to remove dirt from the metals. Please also ensure that you are wearing welding gear and gloves.
  • Draw a line on the upper metal material wherever you want the welds to go. If you're going to use many plug welds, make sure they're uniformly spaced.
  • Begin creating the hole for the welds using the markings you drew on the top metal. This may be accomplished in a variety of methods; however, most welders prefer to use a drill.
  • You'll need to hold the metals together after you've made the holes so they don't move around during you're welding. A plug weld clip is ideal for this.
  • Finally, the weld must be placed. The most essential thing to keep in mind is to begin from the exterior, along with the edges, then work your way within. As a result, the base metal can reach the very same temperature as the uppermost metal material. Improving the weld's strength and lowering the risk of a flaw.

Final Note

The most difficult aspect of plug welding is drilling the holes in the larger piece of metal. It might take a few tries to get it perfect, so keeping some practice metal that's the same size as the item you're dealing on is usually a good idea.

This is true if it's your first time trying to plug weld. Plug welds may be a highly beneficial insertion to your welding abilities with some practice.

However, when done correctly, the plug weld is a far superior alternative to a spot weld and may last longer. So, follow our step steps to plug weld on your own at home.

Last Updated on 2 years by Richard Boyer

  • June 8, 2022
Richard Boyer

Richard Boyer has been a professional welder for over 27 years of his life, and now he is a trainer and blogger providing critical information to anyone interested in welding. He is helping out both hobbyists, novice and professional welders to learn newer and better techniques. Read more about me

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