Table 8.2.2.3.1: (a). Spot-Weld Design Shear Strengtha,b in Thin Sheet and Foil for Uncoated Steelsc and Nickel and Cobalt Alloys (Welding Specification mil-W-6858)

MIL-HDBK-5J, Metallic Materials and Elements for Aerospace Vehicle Structures

Last Updated 29 Oct 2026

Hover any section to copy its link or text, ask Copilot about it, or bookmark it.

Thickness of Thinnest Outer Sheet, in.	Spots/inch		Material Ultimate Tensile Strength, ksi
	Standard (Ns)^d	Range^e,f	Above 185	150 to 185	90 to 149	Below 90
	Standard (Ns)^d	Range^e,f	Design Shear Strength, pounds per linear inch (Xm)
0.001	40	1-50	72	64	52	36
0.002	20	1-30	144	128	104	72
0.003	12	1-17	240	208	164	120
0.004	10	1-14	324	280	228	152
0.005	9	1-13	392	340	272	188
0.006	7	1-10	432	380	304	220
0.007	6	1-8	504	440	352	256
0.008	5	1-7	552	488	392	284

a Strength based on 80 percent of minimum values specified in Specification MIL-W-6858.
b The allowable tensile strength of spot-welds is 25 percent of the design shear strength. Higher values may be used, however, if these are substantiated by tests acceptable to the procuring or certifying agency.
c Refers to plain carbon steels containing not more than 0.15 percent carbon, austenitic, heat and corrosion resistant, and precipitation hardening steels. The reduction in strength of spot-welds due to the cumulative effects of time-temperature-stress factors is not greater than the reduction in strength of the parent metal.
d When the number of spots per inch is within 15 percent of the standard spot per inch requirement, the design shear strengths tabulated above will apply.
e When the number of spots differs from the standard spots per inch by 15 percent or greater, but does not exceed the noted range of spots per inch, applicable design strength will be determined as noted below:

$\frac{\mathrm{Xm}}{\mathrm{Ns}}(\mathrm{K}) \mathrm{Nr}=\mathrm{Xr}$

where

Xm = design shear strength in accordance with the above table Ns = standard spots per inch in accordance with the above table Nr = required spots per inch (production part) Xr = actual design shear strength requirement K = 1.15 when number of spots per inch is reduced more than 15 percent of the standard spacing of the above table K = 0.90 when number of spots is increased more than 15 percent of the standard spacing but within range of the tabular spacing.

f When the number of spots per inch is above the range indicated in the table, the design shear strength will remain constant at the value obtained at the top of the range.

MIL-HDBK-5J