Aerospace Spot Weld Shear Strength: aluminum_alloy
Design-allowable shear load per spot (lbs) for resistance spot welds per MIL-HDBK-5J Section 8.2.2.3 and MIL-W-6858. Indexed by material family (aluminum alloy, steel/nickel/cobalt alloy, magnesium alloy, titanium alloy), parent metal Ftu range (ksi), and sheet thickness (in). Tensile allowable is 25% of shear strength. Covers thicknesses 0.020–0.160 in. No filler metal — allowable is empirical load-per-spot based on sheet thickness and parent metal ultimate tensile strength.
| material family | record id | design shear strength lbs (lbf) | material ftu range ksi | sheet thickness in (in) | tensile allowable lbs (lbf) | tensile allowable note | weld spec |
|---|---|---|---|---|---|---|---|
| aluminum_alloy | alum_ftu_38to56_t0020 | 60 | 38_to_56 | 0.02 | 15 | 25% of shear strength | MIL-W-6858 |
| aluminum_alloy | alum_ftu_38to56_t0025 | 84 | 38_to_56 | 0.025 | 21 | 25% of shear strength | MIL-W-6858 |
| aluminum_alloy | alum_ftu_38to56_t0032 | 120 | 38_to_56 | 0.032 | 30 | 25% of shear strength | MIL-W-6858 |
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