the process was referred to as Metal Inert Gas welding. The GMAW process is currently the most common in
the uni-body repair environment.
Flux Core Arc Welding (FCAW)
• FCAW is an arc welding process where electrode wire is fed through a weld gun and is not surrounded by a
shielding gas.
• The welding zone is protected by the use of flux that is located in the center of electrode wire.
• The surface of the completed will have slag left behind from the flux that will need to be removed prior to any
refinishing process
Metal Active Gas (Mag) Brazing
• MAG brazing, also known as mig brazing is a brazing process where the electrode wire is fed through a weld
gun and is surrounded by argon as shielding gas.
• The application of the process is similar to GMAW. However, it utilizes a different electrode and shielding gas
and does not melt of the base material.
• Due to the lower melting point of the electrode, it produces a much smaller heat affected zone than GMAW.
Weld Bonding
• A method of joining metals using STRSW in conjunction/combination with a structural adhesive.
• Weld bonding provides the customer with a superior repair as compared to the traditional plug/puddle welding
process using GMAW. Structural adhesive should not be used in a joint that did not originally contain it.
• The repair joint or seam should duplicate the OE build as closely as possible, unless otherwise stated in the
collision information.
NOTE: FCA US LLC DOES NOT approve or endorse the use of structural adhesives alone in the
replacement of body panels.
Weld Processes
Squeeze Type Resistance Spot Welding (STRSW)
Applications
• With advancements in equipment technologies, such as computer program controlled and inverters, STRSW is
not restricted to light gauge sheet metal any longer. Heavier gauges of high strength and coated steel,
currently used in vehicle structures, can now be welded in the field, providing destructive testing is performed
on each combination. This is to ensure quality welds are being maintained.
Equipment Requirements
• Equipment must produce two sided welds
• Equipment must have been tested to SAE J2667 with satisfactory results obtained
• Equipment must have the capability to create welds that comply with the Minimum Weld Nugget Requirement
Chart
• Technician must have the appropriate sheet metal measuring equipment to ensure their welds meet the
minimum weld nugget size for the actual panels being welded
Gas Metal Arc Welding (GMAW) or (MIG(
Applications
• Sheet metal repairs where STRSW is not available or practical, and truck frame repairs.
• The most common usage of GMAW on uncoated or galvanneal coated steel will utilize a 75% Argon - 25%
CO2 shielding gas mix, and AWS specification ER70S6 wire. When welding galvanized material, Flux Core
Arc Welding (FCAW) using AWS specification E71T-GS wire should be used to avoid weld porosity from
the zinc in the galvanizing.
Weld Process
COMPONENT
PARTS
TRUCK FRAME
BODYSHELL EXTERIOR & UNDERBODY
PANELS
Zinc and Zinc Iron Alloy coated sheet steels
WELDING PROCESS
GAS METAL
ARC
(Note: 1)
FLUX
CORED ARC
GAS METAL
ARC
(Note: 1)
MAG BRAZE
(Note: 2)
GAS METAL
ARC
(Note: 1)
FLUX
CORED ARC
Material Type
High Strength and Structural Quality Steels which includes HSLA, Martensitic, and Dual
Phase materials
RU 31 - Collision Information 31 - 31
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