I have designed two 22 ga (.79 mm)sheet metal parts out of Phosphor Bronze, or equivalent, with shinny, nickel plating. These parts are to be spot welded together. I am not sure what machine or process the company performing the operation is using but the welds are not holding together. Is the plating contributing to the failure? I don't think that the company has had much experience in doing spot welding, since they are coming to me for help. I have contacted them for the tip diameter and the timing process. Some of the welds do show some spatter marks while others just have a small indent and are able to be pulled apart.

Any help with this will be much appreciated.

Thank you,

Mary Smith Mechanical Design Engineer Rockford Fosgate Corp Tempe, AZ, USA

-- Mary Smith (mary.smith@rockfordcorp.com), January 14, 2004