in Test Weld Coupon. If the weld is insufficient, adjust the welder per the welder manufacturer recommenda-
tions and repeat steps 7, 8 and 9 until the proper weld size is achieved.
NOTE: If the first weld becomes too (hot( before the second weld reaches the correct size, reduce the
current settings for the first weld and continue increasing the current setting for the second weld
until the proper size for the second has been reached.
Final Weld Preparation
CAUTION: All NVH foam must be removed from the repair area of the vehicle, as material is flammable.
1. Visually verify that mating flanges are free of scale, rust, dirt, paint and cured adhesives/sealers, as well
as wrinkles. If cracked, wrinkled or scored metal exists the condition needs to be corrected at this time.
2. E-coat within 25 mm. (1 in.) needs to be removed for STRSW. If Weld Bonding, E-coat should be ground off
completely along seam.
NOTE: Corrosion resistance coating (i.e., galvanneal, galvanized) should not be removed during
cleanup of components.
3. Verify that the welder control settings are the same required to produce the second weld on the test coupons.
4. If adhesive is to be used, apply it at this time. Clamp the component to the vehicle.
NOTE: Insulated clamps should be used, as not to shunt the weld current.
NOTE: During the welding of the component it will be necessary to visually verify that the weld being
made is not placed directly over an existing weld.
5. Perform the welds on the vehicle.
NOTE: Structural adhesive manufacturers will vary on time allowed for completion of weld bond
zones. Check and follow adhesive manufacturer recommendations. Reference the time
temperature chart
(Refer to Non-Structural Sheet Metal Repair/Types of Structural Adhesives).
6. If adhesive was used, clean up any excessive squeezeout prior to adhesive curing.
Training and Qualification
Training
As with any equipment, proper training is required, and in the case of welding equipment this is no exception. The
goal of automobile facilities and technicians is to restore the vehicle to its OEM condition.
Training must be considered a two-fold process:
• The technician must be well versed in how the equipment operates, how adjustments are made and what
effects those adjustments have on the weld. The technician must also clearly understand the maintenance
of the equipment and the impact of poor maintenance on welds and equipment longevity.
• The second and most important, aspect of the training, is weld quality confirmation. Destructive testing of weld
coupons must be performed to ensure the minimum weld size is created. Physical appearance of the weld is
not enough to determine the quality of the weld. Additionally, poor welds may also reduce the durability, or
quality , of the repaired vehicle in time.
It is required that technicians have received training regardless of the welding equipment or method they utilize.
Both training in the specific field of welding, and the particular equipment, are necessary to ensure safe, durable,
quality welds are obtained.
Qualification
To demonstrate welding skill, it is highly important that technicians obtain certification from an organization such as
the American Welding Society (AWS) or a certificate from the Inter-Industry Conference on Auto Collision Repair
(ICAR).
31 - 38 31 - Collision Information RU
To Next Page
Loading...
