Spin Welding Design Guidelines

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Weld Joint Designs

An effective spin-weld joint design consists of interference between the two components’ joints, flash management features, alignment indicators, and drive features to apply torque to both parts. A variety of joint designs can be incorporated to effectively spin weld two components together. A few joint design examples are shown below.


  • Joints should be designed with locating features for part-to-part alignment.
  • To prevent deflection, parts should be designed such that wall thickness is robust enough to resist weld force (50-400 pounds).
  • Adding a return flange adjacent to the weld joint can ensure proper support.


T = Wall Thickness

G = Gap

C = Clearance

D = Weld Depth

R = 1 mm (0.04″)

I = Interference 0.25 to 0.50 mm (0.01″ to 0.02″)

A > 20 degrees

F > D + 0.25 mm (0.01″)

B + E > 2 x T

Flanged Shear

Butt Weld

Tongue & Groove with Flash Trap

Tongue & Groove with External Skirt

Flash Trap and Return Flange Designs

Flash Trap

The flash trap should be designed so the cross-sectional area of the flash trap is greater than the area of the displaced weld rib.

Return Flange

For spin welding thin walled parts, a return flange design can provide added rigidity.

Drive Feature Designs

Drive features are profiles in the part design which provide suitable surfaces to transmit the drive torque during the spin-welding process. They also provide location for loading and orienting the part. Some parts may have inherent drive features, while other designs may require them to be designed into the part.

Drive features may be:

  • notches
  • ribs
  • through-holes
  • other non-circular features

Notches & Ribs

Inherent Part Feature

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