Practice aid
Square end faces help both components stay centered and aligned as they come together during the weld.
When one or both ends are cut at an angle, initial contact happens at a single high point instead of evenly across the mating faces. As welding force brings the parts together, that high point can act like a ramp and make one component skid sideways. The result can be an off-centre joint, uneven weld-nugget formation, reduced effective weld area and lower joint strength.
Why square cuts matter
How an uneven cut makes a weak weld
The wire and the pin start aligned. An angled cut on the pin touches first at one edge, and the wire rides across it.
Schematic, not to scale. After MTI's pin/wire welding practice aid.
The fix
Offset the parts so the high point is supported
A square, burr-free cut is always preferred. If an angled cut cannot be avoided, shift the parts before welding so the high point lands inside the opposing edge.
Direct centerline alignment
The high point of the uneven end is at or beyond the edge of the opposing part. When weld force is applied, the contact geometry encourages the wire or pin to skid sideways.
Slide the offset until the green dot sits inside the wire. Then verify the fixture position with sample welds before production.
Schematic, not to scale. After MTI's pin/wire welding practice aid.
At the bench
Setup checklist
Tick each step as you go.
Key takeaway
Square cuts produce the most stable contact and the most consistent weld alignment. If an uneven cut must be welded, use intentional offset alignment to support the high point of the cut and minimize skid.
FAQ
Why do the ends of the pin and wire need to be cut square?
Square end faces help both components stay centered and aligned as they come together during the weld.
When an end is cut at an angle, the first contact is at a single high point. As weld force brings the parts together, that point can act like a ramp and make one component skid sideways.
What goes wrong when the wire skids?
The joint can be off-centre, the weld nugget forms unevenly, the effective weld area shrinks and joint strength is lower.
What if I cannot avoid an angled cut?
Use offset alignment. Place the parts so the high point of the uneven cut sits inside the corresponding outer edge of the opposing wire or pin, so it is supported instead of left at or beyond the edge. A square, burr-free cut is still always the preferred solution.
How do I confirm my setup?
Inspect the cut faces under magnification when alignment is critical, verify the fixture position with sample welds before production, and check nugget symmetry, final alignment and weld strength as part of first-piece approval.
Still have a question? Tell us your weld challenge and an engineer will reply.
Start here
Send a drawing, a photo or a description of your pin and wire. Free applications tests of your materials are available.
Prefer to talk? Book a demo or call 303-536-7838