Squeeze-Type Resistance Spot Weld Test Coupon Log
Log squeeze-type resistance spot weld test coupon details before vehicle welding, including setup, nugget measurements, photos, and technician sign-off. Use it to document whether the weld setup is ready or needs correction.
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Overview
This template is a pre-weld quality log for squeeze-type resistance spot weld test coupons. It captures the job reference, technician, vehicle, coupon ID, material stackup, machine setting, electrode condition, nugget measurement, result, corrective action, and photo evidence so the team can verify the weld setup before touching the vehicle.
Use it when your process requires a test coupon to confirm that the current weld parameters produce an acceptable nugget size and that the setup matches the intended repair. It is especially useful when the material stackup changes, the electrode condition is questionable, or you need a clear record for quality review. The form is also helpful when a shop wants a consistent sign-off trail tied to a repair order.
Do not use this template as a general incident report, a full repair checklist, or a post-repair inspection form. It is not meant for unrelated quality issues, and it should not be overloaded with optional fields that do not affect the weld test. If your workflow includes multiple test attempts, failed measurements, or corrective adjustments, record each one clearly so the final result is easy to audit.
Standards & compliance context
- Keep the form aligned with data minimization by collecting only the job, setup, measurement, and sign-off fields needed to verify the weld.
- If the form stores technician names or other personal data, include a clear notice about what is collected, why it is collected, and who can access it.
- Use an audit trail or timestamped submission history so the log can support internal quality review and traceability.
- If photos may include people or other sensitive details, define retention and access rules to limit unnecessary exposure of PII.
General regulatory context for orientation only — verify current requirements with counsel or the relevant agency before relying on this template for compliance.
What's inside this template
Job and Technician Details
This section ties the weld test to the correct repair order, date, technician, and vehicle so the record is traceable.
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Repair Order Number
Enter the RO number associated with this repair.
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Date of Test
Select the date the test coupon was completed.
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Technician Name
Enter the name of the structural technician performing the test.
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Vehicle Year / Make / Model
Optional vehicle identifier for shop reference. Do not include VIN unless needed for your internal process.
Test Coupon and Weld Setup
This section captures the exact coupon and machine conditions used for the test, which is what makes the result meaningful.
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Test Coupon ID or Description
Identify the coupon used for the STRSW test.
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Material Stack-Up
Describe the material combination tested, if applicable.
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Weld Machine Setting or Program
Record the setting, program number, or parameters used for the test weld.
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Electrode Condition
Select the condition of the electrodes at the time of testing.
Weld Nugget Results
This section records the measured outcome and any corrective action so pass/fail decisions are backed by evidence.
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Measured Nugget Size (mm)
Enter the measured nugget size in millimeters.
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Measurement Method
Select how the nugget size was verified.
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Test Result
Indicate whether the test coupon met the required weld quality.
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Corrective Action or Notes
Describe any adjustment, re-test, or follow-up action taken after the result.
Photo Documentation and Sign-Off
This section preserves visual proof of the setup and confirms the technician stands behind the completed log.
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Photo Before Welding on Vehicle
Upload a clear photo of the test coupon or setup before welding on the vehicle.
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Additional Supporting File
Optional supporting document such as a second photo or measurement record.
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Technician Attestation
Required acknowledgment for audit trail and quality control.
How to use this template
- 1. Enter the repair order, date, technician name, and vehicle year/make/model so the test coupon log is tied to the correct job.
- 2. Record the coupon ID, material stackup, weld machine setting, and electrode condition before making the test weld so the setup is documented as used.
- 3. Attach the pre-weld photo and any additional file that shows the coupon or setup condition before the weld is performed.
- 4. Measure the weld nugget using the selected method, enter the size in millimeters, and mark the result as pass or fail based on your shop standard.
- 5. Add any corrective action taken after a failed result, then complete the technician attestation to confirm the record is accurate and complete.
Best practices
- Match the coupon material stackup to the vehicle repair stackup so the test result reflects the actual weld condition.
- Use a numeric field for nugget size and a controlled field for the measurement method so the record stays consistent.
- Photograph the coupon before welding and keep the image attached to the same log entry to preserve traceability.
- Record electrode condition at the time of the test instead of relying on memory after the weld is complete.
- Use conditional logic for corrective action details so the form expands only when the result is marked fail.
- Keep required fields limited to the data needed to verify the weld and identify the job, which supports data minimization.
- Review the log before sign-off to catch missing photos, mismatched repair order numbers, or vague result entries.
What this template typically catches
Issues teams running this template most often surface in practice:
Common use cases
Frequently asked questions
When should this test coupon log be used?
Use it before welding on the vehicle, after you have set up the machine and prepared a test coupon that matches the intended material stackup. It is meant to confirm the weld nugget and setup are acceptable before production work starts. If the setup changes during the job, create a new log entry for the new condition.
Who should complete the log?
The technician performing the weld test should complete the form, with a supervisor or quality reviewer signing off if your process requires it. The person entering the data should be the one who can confirm the machine setting, electrode condition, and measured nugget result. That keeps the record tied to the actual work performed.
What does this template actually capture?
It captures the repair order reference, date, technician name, vehicle details, coupon ID, material stackup, weld machine setting, electrode condition, nugget size, measurement method, result, corrective action, and photo documentation. It also includes a technician attestation so the log can serve as a traceable quality record. The template is focused on pre-weld verification, not the full repair process.
How often should a new coupon log be created?
Create a new log whenever the vehicle, material stackup, machine setting, electrode condition, or repair order changes in a way that affects the weld test. Many shops also start a new log at the beginning of each job or shift to keep records clean and easy to audit. If your process requires multiple test attempts, record each attempt separately.
What are the most common mistakes when using this form?
Common mistakes include skipping the pre-weld photo, entering a vague measurement method, or recording a result without noting the corrective action. Another issue is using the same log for different stackups or machine settings, which makes the record hard to trust. The form works best when each field is completed with the specific test condition that was actually used.
Can this template be customized for different shop processes?
Yes. You can add fields for additional electrode checks, supervisor approval, or internal quality codes if your workflow needs them. Keep the form lean by using conditional logic so extra fields only appear when they apply. That helps avoid unnecessary data entry and supports data minimization.
Does this log integrate with other quality records?
It can be linked to repair orders, inspection records, photo attachments, and corrective action tracking. Many teams connect it to a quality dashboard or document storage system so the test record stays with the job file. If you already use a work order system, map the repair order field to that record for easier retrieval.
How does this compare with a handwritten shop note?
A handwritten note often misses key details like measurement method, photo evidence, or a clear sign-off, which makes review harder later. This template standardizes the fields so every test coupon log captures the same minimum set of facts. That improves consistency, traceability, and follow-up when a weld needs correction.
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