WORK NOTICES AND PRECAUTIONS > PRECAUTIONS FOR WELDING



REMOVAL OF ADJACENT COMPONENTS


    K100267

  1. To prevent damage to the body and parts, apply protective tape to the body and tools before removing the parts.

    NOTICE:
    If the paint film is damaged, make sure to refinish the paint.


ANTI-RUST TREATMENT BEFORE WELDING


    K100268

  1. Apply welding primer to the contact surfaces of the welding areas to protect them from rust.

    NOTICE:
    Do not apply welding primer outside of the contact surfaces.


WELDING WORK


    K100269E01
    K100272E01

  1. Follow the welding conditions below when welding ultra high strength steel to assure sufficient weld strength.
    Text in Illustration 
    *1
    		980 MPa Ultra High Strength Steel
    When welding 2 panels together including 980 MPa ultra high strength steel. 
    Spot weld
    		Pressure
    		2940 N (300 kgf, 661 lbf)
    Weld current
    		10000 A
    Weld time
    		16 Cyc. (0.27 Sec.)
    Plug weld
    		Plug diameter
    		10 mm (0.39 in.)
    Wire type
    		AWS A5.18 ER70S-3
    Shield gas
    		Metal active gas

    NOTICE:
    Be sure to use Metal active gas (Ar 80% + CO2 20%) as the shield gas when plug welding. Sufficient weld strength cannot be assured when using 100% CO2 shield gas.

    Text in Illustration 
    *2
    		980 MPa Ultra High Strength Steel
    When welding more than 3 panels together including 980 MPa ultra high strength steel. (When welding a third panel to two panels which are welded under the conditions described above.) 
    Plug weld
    		Plug diameter
    		Same as the standard method
    (See the introduction)
    Wire type
    		AWS A5.18 ER70S-3
    Shield gas
    		Metal active gas

    NOTICE:
    Be sure to use Metal active gas (Ar 80% + CO2 20%) as the shield gas when plug welding. Sufficient weld strength cannot be assured when using 100% CO2 shield gas.

  2. Standard Number of Welds

    980 MPa ultra high strength steel
    		Number of spot welds
    		More than the number of welds made by the manufacturer
    Number of plug welds
    		More than the number of welds made by the manufacturer
    Normal steel or high strength steel
    		Number of spot welds
    		More than 1.3x the number of welds made by the manufacturer
    Number of plug welds
    		More than the number of welds made by the manufacturer

    NOTICE:
    Inspect the welds after spot welding. For points with insufficient weld strength join the panels using plug welds.



    3. K100274E01

  3. Spot weld locations
    Text in Illustration 
    *1
    		Old Spot Locations
    *2
    		New Spot Locations
    Avoid welding over previously welded areas.


MAKING HOLES FOR PLUG WELDING
K100275E01
Text in Illustration 
*1
Puncher

  1. For areas where a spot welder cannot be used, use a puncher or drill to make holes for plug welding.
    Thickness of welded portion
    		Diameter of plug hole
    Under 1.0 mm (0.04 in.)
    		Over 5.0 mm (0.20 in.)
    1.0 to 1.6 mm (0.04 to 0.06 in.)
    		Over 6.5 mm (0.26 in.)
    1.7 to 2.3 mm (0.07 to 0.09 in.)
    		Over 8.0 mm (0.31 in.)
    Over 2.4 mm (0.09 in.)
    		Over 10 mm (0.39 in.)