Plug welding in collision repair is used to?

• A. To replace factory spot welds when resistance welding is not possible
• B. To join two metal plates end to end
• C. To seal gaps to prevent rust
• D. To attach trim pieces

Answer: (A)

Plug welding is used in collision repair to secure a patch panel by welding through holes in the patch into the underlying metal when you can’t access or perform traditional resistance spot welding. This method recreates the holding power of spot welds from a single side, making it ideal when the backside isn’t reachable or when the panel geometry prevents normal spot welding. It creates a series of welds that bind the two sheets together along the seam, restoring function and strength. It is not intended for joining panels end to end, sealing gaps, or attaching trim pieces.