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Glossary

Plug weld

A weld made by drilling a hole in one part, then filling the hole with weld metal that bonds to the part underneath. Used to fix overlapping plates.

A plug weld is created by drilling a round hole through one of two overlapping members, then filling the hole with weld metal that fuses to the lower member. The result is a strong shear-resistant joint without welding around the perimeter of the upper member.

Plug welds are common where you need to fix a stiffener plate to a face without a visible perimeter weld, where access for a perimeter weld is restricted, or where the upper member is too thin to weld at its edge without burning through.

The slot weld is a related variant: instead of a round hole, a slot is cut and filled with weld metal. Slot welds give more shear capacity than a single plug for the same amount of weld metal.

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