Aerospace Spot Weld Shear Strength: steel nickel cobalt
steel ftu above220 t0050 to steel ftu below150 t0050
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 |
|---|---|---|---|---|---|---|---|---|
| steel nickel cobalt | steel ftu above220 t0050 | 920 | above 220 | 0.05 | MIL-HDBK-5J Section 8.2.2.3 | 230 | 25% of shear strength | MIL-W-6858 |
| steel nickel cobalt | steel ftu above220 t0063 | 1,200 | above 220 | 0.063 | MIL-HDBK-5J Section 8.2.2.3 | 300 | 25% of shear strength | MIL-W-6858 |
| steel nickel cobalt | steel ftu above220 t0080 | 1,560 | above 220 | 0.08 | MIL-HDBK-5J Section 8.2.2.3 | 390 | 25% of shear strength | MIL-W-6858 |
| steel nickel cobalt | steel ftu above220 t0100 | 2,000 | above 220 | 0.1 | MIL-HDBK-5J Section 8.2.2.3 | 500 | 25% of shear strength | MIL-W-6858 |
| steel nickel cobalt | steel ftu above220 t0125 | 2,600 | above 220 | 0.125 | MIL-HDBK-5J Section 8.2.2.3 | 650 | 25% of shear strength | MIL-W-6858 |
| steel nickel cobalt | steel ftu above220 t0160 | 3,400 | above 220 | 0.16 | MIL-HDBK-5J Section 8.2.2.3 | 850 | 25% of shear strength | MIL-W-6858 |
| steel nickel cobalt | steel ftu below150 t0025 | 200 | below 150 | 0.025 | MIL-HDBK-5J Section 8.2.2.3 | 50 | 25% of shear strength | MIL-W-6858 |
| steel nickel cobalt | steel ftu below150 t0032 | 280 | below 150 | 0.032 | MIL-HDBK-5J Section 8.2.2.3 | 70 | 25% of shear strength | MIL-W-6858 |
| steel nickel cobalt | steel ftu below150 t0040 | 380 | below 150 | 0.04 | MIL-HDBK-5J Section 8.2.2.3 | 95 | 25% of shear strength | MIL-W-6858 |
| steel nickel cobalt | steel ftu below150 t0050 | 520 | below 150 | 0.05 | MIL-HDBK-5J Section 8.2.2.3 | 130 | 25% of shear strength | MIL-W-6858 |
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