Welding Precautions — Steel

  General Specifications

 WARNING: Invisible ultraviolet and infrared rays emitted in welding can injure unprotected eyes and skin. Always use protection such as a welder's helmet with dark-colored filter lenses of the correct density. Electric welding will produce intense radiation, therefore, filter plate lenses of the deepest shade providing adequate visibility are recommended. It is strongly recommended that persons working in the weld area wear flash safety goggles. Also wear protective clothing. Failure to follow these instructions may result in serious personal injury.

 WARNING: On vehicles equipped with Safety Canopy® options, prior to carrying out any sectioning repairs near the roof line or sail panel areas of the vehicle, remove the Safety Canopy® module and related components. Failure to comply may result in accidental deployment or damage to the Safety Canopy®. Refer to Section 501-20B . Failure to follow these instructions may result in serious injury to technician or vehicle occupant(s).

NOTE: When carrying out test welds using Metal Inert Gas (MIG) plug welding or spot welding techniques, refer to Weld Nugget Chart in Specifications in this section.

The correct equipment and settings must be used when welding mild or high-strength steel. MIG and resistance spot welding Squeeze-Type Resistance Spot Welding (STRW) are the preferred methods. Surfaces must be clean and free of foreign materials.

• Correct eye protection must be worn.
• The correct protective clothing should always be worn.
• Adequate ventilation must be provided to avoid accumulation of poisonous gases.
• A test weld should always be carried out on a test sample.
• Use cleaning brushes and abrasive grinding wheels dedicated to the type of materials being welded.
• Follow the equipment manufacturer's prescribed procedures and equipment settings for the type of welder being used. ER70S-3 or ER70S-6 wire are typically used for MIG welding steel.
• Disconnect the battery ground cable. Refer to Section 414-01 .
• Disconnect on-vehicle modules adjacent to the welding area and protect them from possible heat damage and electrical currents when welding.
• Corrosion protection must be restored whenever bare metal repairs are made. Refer to Restoring Corrosion Protection Following Repair in this section.
• Adequate power supply needs to be used to make sure of correct equipment performance.
• Factory spot welds may be substituted with either STRW or MIG plug welds. Spot/plug welds should equal factory welds in both location and quantity. Do not place a new spot weld directly over an original weld location. Plug weld hole should equal 8 mm (0.31 in) diameter.

Welding Precautions — Dual-Phase Steel

 WARNING: Invisible ultraviolet and infrared rays emitted in welding can injure unprotected eyes and skin. Always use protection such as a welder's helmet with dark-colored filter lenses of the correct density. Electric welding will produce intense radiation, therefore, filter plate lenses of the deepest shade providing adequate visibility are recommended. It is strongly recommended that persons working in the weld area wear flash safety goggles. Also wear protective clothing. Failure to follow these instructions may result in serious personal injury.

 WARNING: On vehicles equipped with Safety Canopy® options, prior to carrying out any sectioning repairs near the roof line or sail panel areas of the vehicle, remove the Safety Canopy® module and related components. Failure to comply may result in accidental deployment or damage to the Safety Canopy®. Refer to Section 501-20B . Failure to follow these instructions may result in serious injury to technician or vehicle occupant(s).

The correct equipment and settings must be used when welding dual-phase steel. MIG and STRW are the recommended methods. Surfaces must be clean and free of foreign materials.

ER70-S-6 is the recommended wire specification to use when welding dual-phase steel components.

Recommended gas mixtures are as follows: C02, 92Ar8C02, 84Ar16C02 and 77Ar23C02.

Components made of dual-phase steel should not be heated to straighten or repair. New components should be installed if severely bent or kinked.

Do not use Oxyacetylene equipment to weld dual-phase steel.

• Correct eye protection must be worn.
• The correct protective clothing should always be worn.
• Adequate ventilation must be provided to avoid the accumulation of poisonous gases.
• A test weld should always be carried out on a test sample.
• Use cleaning brushes and abrasive grinding wheels dedicated to the type of materials being welded.
• Follow the equipment manufacturer's prescribed procedures and equipment settings for the type of welder being used.
• Disconnect the battery ground cable. Refer to Section 414-01 .
• Disconnect on-vehicle modules adjacent to the welding area and protect them from possible heat damage and electrical currents when welding.
• Corrosion protection must be restored whenever bare metal repairs are made. Refer to Restoring Corrosion Protection Following Repair in this section.
• Adequate power supply needs to be used to make sure of correct equipment performance.
• Factory spot welds may be substituted with either STRW or MIG plug welds. Spot/plug welds should equal factory welds in both location and quantity. Do not place a new spot weld directly over an original weld location. Plug weld hole should equal 8 mm (0.31 in) diameter.