What Is Plug Welding?

Plug welding is a non-pressure fusion process that is becoming increasingly popular in various industries, such as automobile production. It is used to join two metal parts together at their edges by connecting them with electrical currents.

With its low cost, ease of use, and a very wide range of applications, plug welding is becoming an increasingly common method of connecting components. In fact, the number of plug welding applications has grown so much in recent years that the market for plug welding machines has grown by over 10% annually since 201 So, what is plug welding and how can it benefit your project?

Read on to find out.

What is Plug Welding?

Plug welding, also known as spot welding, is a type of welding process used to join two metal parts together by introducing heat and pressure at a local spot. It is a very effective and efficient way of welding, for welding thicknesses of 0.

3 – 8mm. It is used when fabrication engineers try to weld together two metal parts, typically steel, with an overlap connection between them.

Types of Plug Welding

Plug welding can be done in two different ways. This includes:
  • Resistance Plug Welding
  • Arc Plug Welding

Resistance Plug Welding

Resistance plug welding is the most common type of plug welding.

In resistance plug welding, an electrical current is passed through the two metal parts to generate heat. The current creates an arc at the joint point of the two metal pieces, which allows for the two pieces to be fused together.

Arc Plug Welding

Arc plug welding is a more complex type of plug welding.

This type of welding requires the use of a tungsten electrode that is heated with an electric current to create an arc. The tungsten electrode then melts the metal pieces in contact with the electrode, allowing for a stronger bond.

Advantages and Disadvantages of Plug Welding

Plug welding has some advantages, as well as disadvantages.
  • Advantages
    • It is a fast process, with a welding time of less than a second.
    • It is a reliable and efficient method of welding.

    • The cost of welding is low as there are no materials used other than the electrode, making it economical.
  • Disadvantages
    • It is limited to welding in small areas, and cannot be used to weld large pieces.
    • The heat generated during welding can distort the metal if not accounted for.
    • It can be more difficult to weld aluminum and other non-ferrous metals.


Plug welding is a fast, reliable, and efficient way of welding, with minimal cost. It is used in many different industries, such as automotive and manufacturing, to join two metal parts together. However, it is important to consider the limitations of plug welding as it can only be used in small areas and can be difficult to weld non-ferrous metals. Citation URL: http://www. dengarden. com/home-improvement/Welding-Basics-A-Beginners-Guide https://en. wikipedia. org/wiki/Plug_weldinghttps://www. interempresas. net/definiciones/plug-welding-36html

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