Welding precautions, steel panels (Panel repairs)

WELDING PRECAUTIONS, STEEL PANELS

For ease of reference the diagrams on the following pages show only the type of weld used, where this varies from that used in production.

When carrying out welding operations the following criteria must be observed:

• Where resistance spot welds have been used in production, these must be reproduced with new spot welds in replacement where possible. All such reproduction spot welds must be spaced 30mm (1 3/16 in) apart.
• When spot welding, it is recommended that test coupons of the same metal gauges and materials are produced to carry out

A. Single thickness plug welds

peel tests to ensure that welding equipment being used can produce a

B. Multiple thickness plug welds

satisfactory joint. Plug welds must be used if a satisfactory spot weld cannot be

C. MIG seam weld

produced.

• The electrode arms on hand-held spot

Impacts which do not deploy airbags

welding guns must not exceed 300mm (11 13/16 in) in length.

• Single-sided spot welding is not acceptable.

longitudinals, crash cans and bracketry.

• Brazing and gas welding are not

Seat Belt Anchorages

acceptable EXCEPT where they have been

Seat belt anchorages are safety critical. When making

specified in production.

repairs in these areas it is essential to follow design specifications. Note that High Strength Low Alloy

• Where 3 metal thicknesses or more are to

(HSLA) steel may be used for seat belt anchorages.

be welded together it is imperative to use MIG plug welds to ensure joint strength.

Where possible, the original production assembly should be used, complete with its seat belt

• MIG plug welds must be used in repair

anchorages, or the cut line should be so arranged that

joints where there is no access for a

the original seatbelt anchorage is not disturbed.

resistance spot welder. To replace each production spot weld a hole must be drilled

All welds within 250mm (9 7/8 in) of seat belt

and/or punched, and a MIG weld then

anchorages must be carefully checked for weld

made in its place. The number of plug

quality, including spacing of spot welds.

welds must match exactly the number of spot welds which have been removed.

• Where holes are left in an existing panel after removal of the spot welds, a single

the welds in these areas are safety critical and

MIG plug weld will be made in each hole as

cannot be disturbed.

appropriate.

• The replacement welds in the welding diagrams are denoted by the following symbols:

• CAUTION: Check for structural damage in
• the area of the impact, paying particular
• attention to bumper armature,

• WARNING: Body parts incorporating seat
• belt anchorages MUST be renewed
• completely if damaged beyond repair, as