disc should be used to remove the E-coat without damaging other sheet metal coatings
• With advancements in technology some STRSW welders now have computer controlled programs. These
technologically advanced welders are capable of measuring the thickness and resistance of the panels being
welded including multiple tiers and types of metal. The computer program is able to process the information to
provide the proper spot weld consistently.
• If the panel originally had structural adhesives it should be reapplied prior to welding. The adhesive should
have a corrosion inhibitor and cover all bare metal.
• Prior to creating weld coupons and the final body repairs, all coatings and dirt/road debris must be removed.
Testing
• Weld coupons identical to the repair situation need to be made prior to performing any repair. These coupons
must be tested (peel test) to determine if the weld nugget meets the minimum size outlined above in the
Minimum Weld Nugget Requirement Chart. Keep in mind that different material coatings, coating thickness,
material thickness, and joint configurations have a direct impact on nugget size.
Weld Bonding
NOTE: Structural adhesive manufacturers will vary on time allowed for completion of STRSW in weld bond
zones. Check and follow adhesive manufacturer recommendations.
Application
• Weld bonding is the STRSW welding process utilizing structural adhesive between the panels that are
resistance welded together. The adhesive creates a very stiff structure, while the welding eliminates concerns
of the adhesives’ peel strength.
• Additionally, the adhesive acts as a sealer and provides a high level of corrosion protection.
Sealers and Adhesives
• Sealers are materials placed on top of a seam to control water and air intrusion.
• Adhesives, providing structural improvements, are found between panels welded together. Adhesives also
provide the qualities of sealers when applied correctly.
• The FCA US LLC recommendation is to replace any suspected adhesive with a two-component, corrosion
inhibiting structural adhesive when any repairs are made, providing the STRSW process is applicable.
31 - 34 31 - Collision Information RU
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