In addition, higher strength steels may require special techniques or treatments like tempering after welding. Spot weldability of HSLA (high-strength low-alloy) steels is directly related to composition and type of microalloying elements. It is advisable to check with the supplier before specifying spot welding here. Stainless steels are spot weldable, some grades more readily than others. Austenitic grades of the 300 series are the most commonly welded types, followed by ferritic. Martensitic stainlesses are the least common because welded joints are always much more brittle. All stainless steels require careful adjustment of welding parameters and/or special methods to obtain optimum quality welds.

Start off by drilling 7.5mm holes in the front sheet of metal at a spacing of normally 25mm to 40mm (or whatever the original spot weld spacing was). Then clamp this sheet onto the back sheet. 7.5mm is a reasonably good hole size for 0.8 or 1.0mm sheet. Thicker sheet might require a slightly larger hole size. Try a little test piece out like this one before welding a whole sill onto a car and check the weld has penetrated through both sheets.

Materials Appropriate for Spot Welding: Due to its lower thermal conductivity and higher electrical resistance, steel is comparatively easy to spot weld, with low carbon steel being most suited to spot welding. However, high carbon content steels (Carbon equivalence > 0.4wt%) are prone to poor fracture toughness or cracking in the welds as they tend to form hard and brittle microstructures. Galvanised steel (zinc coated) requires slightly higher welding currents to weld than uncoated steels. Also, with zinc alloys, the copper electrodes rapidly degrade the surface and lead to a loss of weld quality. When spot welding zinc coated steels, electrodes must either be frequently exchanged or the electrode tip surface should be ‘dressed’, where a cutter removes contaminated material to expose a clean copper surface and reshapes the electrode. See more info at Spot Welder.

Portable spot welders are compact, lightweight and handy for difficult-to-access joints. As such, they are most commonly used in coachbuilding. They have an average welding capacity of 2 + 2mm and are relatively inefficient due to the fact that the electrodes aren’t cooled between cycles. Automatic adjustment makes it easier to adjust the spot parameters according to the thickness of sheet and welding head used.