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6 Thermal joining techniques
This chapter provides details about the thermal joining processes
currently used in body welding work.
6.1 Resistance spot welding (RP)
When performing welding repairs, the original joint should always
be restored wherever possible.
To do so, the following requirements must be fulfilled:
♦ The panels which are to be welded must overlap.
♦ The welding point must be accessible on both sides for the
electrodes.
♦ The resistance spot welder must have sufficient power to
make spot welds of the original diameter.
For body repair work, access to the welding points may vary; a
full set of the electrode versions most commonly used must be
available for each resistance spot welder.
RP welding of galvanised panels
Note the following points when resistance spot welding galvan‐
ised panels:
♦ The flanges to be welded must make contact. If necessary,
clamp the flanges together.
♦ This is particularly important on high-strength steel panels, as
the electrode force will otherwise not be sufficient.
♦ Make sure you do not make spot welds with welding tongs
directly next to the clamps, as this would allow a large propor‐
tion of the welding current to drain off in a shunt circuit.
♦ If the distance between the spot welds is small, place spot
welds in a row or secure by initially welding every third spot
and then fill in the remaining spots. This helps to reduce the
effect of a shunt current.
♦ Please observe the operating instructions and the information
on correct settings provided by the manufacturer of the weld‐
ing equipment.
General InformationBody Repairs, General Body Repairs - Edition 04.2018
6. Thermal joining techniques 23
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