Aerospace Spot Weld Shear Strength: aluminum alloy
alum ftu below38 t0020 to alum ftu below38 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 below38 t0020 | 48 | below 38 | 0.02 | MIL-HDBK-5J Section 8.2.2.3 | 12 | 25% of shear strength | MIL-W-6858 |
| aluminum alloy | alum ftu below38 t0025 | 68 | below 38 | 0.025 | MIL-HDBK-5J Section 8.2.2.3 | 17 | 25% of shear strength | MIL-W-6858 |
| aluminum alloy | alum ftu below38 t0032 | 96 | below 38 | 0.032 | MIL-HDBK-5J Section 8.2.2.3 | 24 | 25% of shear strength | MIL-W-6858 |
| aluminum alloy | alum ftu below38 t0040 | 136 | below 38 | 0.04 | MIL-HDBK-5J Section 8.2.2.3 | 34 | 25% of shear strength | MIL-W-6858 |
| aluminum alloy | alum ftu below38 t0050 | 192 | below 38 | 0.05 | MIL-HDBK-5J Section 8.2.2.3 | 48 | 25% of shear strength | MIL-W-6858 |
| aluminum alloy | alum ftu below38 t0063 | 276 | below 38 | 0.063 | MIL-HDBK-5J Section 8.2.2.3 | 69 | 25% of shear strength | MIL-W-6858 |
| aluminum alloy | alum ftu below38 t0080 | 376 | below 38 | 0.08 | MIL-HDBK-5J Section 8.2.2.3 | 94 | 25% of shear strength | MIL-W-6858 |
| aluminum alloy | alum ftu below38 t0100 | 504 | below 38 | 0.1 | MIL-HDBK-5J Section 8.2.2.3 | 126 | 25% of shear strength | MIL-W-6858 |
| aluminum alloy | alum ftu below38 t0125 | 644 | below 38 | 0.125 | MIL-HDBK-5J Section 8.2.2.3 | 161 | 25% of shear strength | MIL-W-6858 |
| aluminum alloy | alum ftu below38 t0160 | 880 | below 38 | 0.16 | MIL-HDBK-5J Section 8.2.2.3 | 220 | 25% of shear strength | MIL-W-6858 |
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