Aerospace Spot Weld Shear Strength: aluminum alloy
alum ftu above56 t0020 to alum ftu above56 t0160
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) | standard | tensile allowable lbs (lbf) | tensile allowable note | weld spec |
|---|---|---|---|---|---|---|---|---|
| aluminum alloy | alum ftu above56 t0020 | 68 | above 56 | 0.02 | MIL-HDBK-5J Section 8.2.2.3 | 17 | 25% of shear strength | MIL-W-6858 |
| aluminum alloy | alum ftu above56 t0025 | 96 | above 56 | 0.025 | MIL-HDBK-5J Section 8.2.2.3 | 24 | 25% of shear strength | MIL-W-6858 |
| aluminum alloy | alum ftu above56 t0032 | 140 | above 56 | 0.032 | MIL-HDBK-5J Section 8.2.2.3 | 35 | 25% of shear strength | MIL-W-6858 |
| aluminum alloy | alum ftu above56 t0040 | 196 | above 56 | 0.04 | MIL-HDBK-5J Section 8.2.2.3 | 49 | 25% of shear strength | MIL-W-6858 |
| aluminum alloy | alum ftu above56 t0050 | 276 | above 56 | 0.05 | MIL-HDBK-5J Section 8.2.2.3 | 69 | 25% of shear strength | MIL-W-6858 |
| aluminum alloy | alum ftu above56 t0063 | 396 | above 56 | 0.063 | MIL-HDBK-5J Section 8.2.2.3 | 99 | 25% of shear strength | MIL-W-6858 |
| aluminum alloy | alum ftu above56 t0080 | 536 | above 56 | 0.08 | MIL-HDBK-5J Section 8.2.2.3 | 134 | 25% of shear strength | MIL-W-6858 |
| aluminum alloy | alum ftu above56 t0100 | 720 | above 56 | 0.1 | MIL-HDBK-5J Section 8.2.2.3 | 180 | 25% of shear strength | MIL-W-6858 |
| aluminum alloy | alum ftu above56 t0125 | 920 | above 56 | 0.125 | MIL-HDBK-5J Section 8.2.2.3 | 230 | 25% of shear strength | MIL-W-6858 |
| aluminum alloy | alum ftu above56 t0160 | 1,296 | above 56 | 0.16 | MIL-HDBK-5J Section 8.2.2.3 | 324 | 25% of shear strength | MIL-W-6858 |
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