Aerospace Spot Weld Shear Strength: magnesium alloy
mag ftu below32 t0032 to mag ftu below32 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 |
|---|---|---|---|---|---|---|---|---|
| magnesium alloy | mag ftu below32 t0032 | 76 | below 32 | 0.032 | MIL-HDBK-5J Section 8.2.2.3 | 19 | 25% of shear strength | MIL-W-6858 |
| magnesium alloy | mag ftu below32 t0040 | 108 | below 32 | 0.04 | MIL-HDBK-5J Section 8.2.2.3 | 27 | 25% of shear strength | MIL-W-6858 |
| magnesium alloy | mag ftu below32 t0050 | 148 | below 32 | 0.05 | MIL-HDBK-5J Section 8.2.2.3 | 37 | 25% of shear strength | MIL-W-6858 |
| magnesium alloy | mag ftu below32 t0063 | 208 | below 32 | 0.063 | MIL-HDBK-5J Section 8.2.2.3 | 52 | 25% of shear strength | MIL-W-6858 |
| magnesium alloy | mag ftu below32 t0080 | 280 | below 32 | 0.08 | MIL-HDBK-5J Section 8.2.2.3 | 70 | 25% of shear strength | MIL-W-6858 |
| magnesium alloy | mag ftu below32 t0100 | 376 | below 32 | 0.1 | MIL-HDBK-5J Section 8.2.2.3 | 94 | 25% of shear strength | MIL-W-6858 |
| magnesium alloy | mag ftu below32 t0125 | 488 | below 32 | 0.125 | MIL-HDBK-5J Section 8.2.2.3 | 122 | 25% of shear strength | MIL-W-6858 |
| magnesium alloy | mag ftu below32 t0160 | 640 | below 32 | 0.16 | MIL-HDBK-5J Section 8.2.2.3 | 160 | 25% of shear strength | MIL-W-6858 |
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