PENGELASAN

Body Instructor Course Step 1
Welding
TOYOTA MOTOR CORPORATION

1. Welding types
(1) Pressure Welding Spot Welding
Carbon Dioxide arc welding

(2) Fusion Welding Metal Active Gas welding
Metal Inert Gas Welding
(3) Braze Welding Hard Brazing (brass)

Recommended Welding Methods
1. The welding method used must be spot welding, CO2
MIG/MAG welding.
2. Brazing must not be performed at areas other than those

instructed by the vehicle manufacturer.
3. Oxy-acetylene welding must not be used.

Resistance Spot
Contents Welding
• Coated steels & Welding coated
steels
• High Strength Steels & Applications
• Welding High Strength Steels
• Stages of Spot Welding operation
MIG/MAG
Contents
Welding
• Gas shielded welding
• Gases used for shielded arc process
• Welding transfer
• Welding wire types
Coated Steels
Single sided Zinc coated steels
Coated Steels
Double-sided Zinc coated steels
Applications of
Coated steels
Welding coated steels
Panel Welding:
• The paint as well as the Zinc portion must
be removed completely before welding.
Care should be taken when removing this
coating
• A weld through primer (brush-on) should
be used on the prepared faces before spot
welding
• Electrodes will often “pick up” particles of
coating - Clean tips frequently
High Strength
Steels (HSS)
What are High Strength Steels ?
• Low Carbon Steels with addition
micro-alloying elements:
MANGANESE
NIOBIUM
TITANIUM
(SILICON)
Advantages &
Disadvantages of HSS
Advantages:
• To increase strength & reduce weight
• Which will increase fuel economy and
performance
Disadvantages:
• Lose strength & change in ductility
when overheated
Application of High
Strength Steels
Characteristics of Spot
Welding
1. Due to its short weld time and localized heat
application, practically no distortion occurs.
2. It is most suitable for welding thin plates.
3. It does not require much skill or experience.
4. Due to the large electrical current required,

the welding unit tends to be heavy.
Spot Welding Operation
THREE STAGES
• SQUEEZE TIME: The first stage, when the
electrodes are brought together against the
metal before the flow of current.
• WELD TIME: The second stage, when the
current is flowing.
• HOLD TIME: The final stage, when the
current flow has finished but the pressure is
maintained.
Spot Welding operation
Welding Conditions
Welding Conditions
Spot Welding operation
Heat application
IMPORTANCE OF
WELD TIME
• Strength depends on the correct depth
of fusion.
• Sufficient time is required to produce
correct depth of fusion.
• Temperature must be high enough to
ensure proper fusion of the two welds.
Heat application
IMPORTANCE OF
WELD TIME
• If temperature is too great, cavities
and cracks may appear.
• In High Strength Steel cracking in the
vicinity of HAZ could appear after the
completion of the welding operation.
Electrodes
Copper alloy electrodes
Electrodes
Tip Condition
• The diameter of the spot decreases as the
diameter of the electrode tip increases.
• If the tip is too small, the spot weld will
not increase in size.
• If tips are worn, dirty, etc. Reshape tips.
• Misalignment of electrodes (and tips) and
incorrect pressure will produce defective
welds
Electrodes
Electrodes
THE FUNCTION OF THE ELECTRODE
• To conduct the current to the weld area

• To provide the necessary clamping force
to produce the weld
• To aid heat dissipation from the weld
area
Electrodes
IMPORTANT POINTS
• The adjustment of electrode clamping
force is critical for HSS
• The adjustment of electrode clamping
force is critical when long arms are used
and when used in complex situations, for
example; Wheel arches
Weld quality
Factors affecting weld quality
• Type of metal being welded
• Joint configuration
• Current & timer settings
• The type of welding equipment being
used
• Electrode Maintenance
Weld quality
Weld quality
• Any clearance between the surfaces
causes poor current flow
• Contamination on the metal surface
causes insufficient current flow
• Metals with zinc coated surfaces should
be prepared with an anti-corrosion agent
before welding
• The strength of the spot welds is
determined by the weld pitch.
Weld quality
• A = Reactive current A
C
diversion (shunting)
• B = Weld pitch
• C = Electrodes B C
Weld quality
Position of the spot welds
Weld quality
Inspection of spot welds
• ABNORMALITY: Weld nugget size too
small
• CAUSES: Insufficient current, excessive
pressure applied, weld time too short
Weld quality
• ABNORMALITY: Too much internal weld
spatter
• CAUSES: Excessive current, Insufficient
pressure, dirty surface
Weld quality
• ABNORMALITY: Blow holes
• CAUSES: Insufficient pressure, Insufficient
hold time
Weld quality
• ABNORMALITY: Cracks
• CAUSES: Insufficient pressure, shape of the
tip is incorrect
Weld quality
• ABNORMALITY: Excessive depression
• CAUSES: Excessive pressure applied,
Excessive current, Tip end is too sharp
Weld quality
• ABNORMALITY: Explosion
• CAUSES: Extreme current excess, Extreme
pressure deficiency
Weld testing
DESTRUCTIVE TEST
Weld Testing
NON DESTRUCTIVE TESTING
Weld testing HSS
Types of spot weld failure
Welding equipment
• Two sided welders should always be used
for spot welds
• Hand-held pincer type guns with
powerful transformer (to maintain the
very short weld times)
• This type of machine can either be water
cooled and/or air cooled
• The equipment should be at least 8800A
(to produce high quality welds)
Thank you
for your
attention
MIG/MAG Welding
MIG/MAG Welding
• Metal inert gas (MIG) welding

- Gas used; argon & helium
• Metal active gas (MAG) welding

- Gas used; carbon dioxide or
argon/carbon dioxide mixtures
Welding gas
FUNCTION OF THE GAS
• Protection from atmospheric
contamination
• To support and stabilise the arc
• Control of the weld bead geometry
• Control of the weld metal properties
Welding gas
ARGON:
• Inert Gas (does not burn, support
combustion)
• Prevent oxidation or chemical reaction
taking place during welding process
Welding gas
• Advantages of Argon:
- Smooth & quiet arc action
- Lower arc voltage
- Cleaner action of welding of materials
- Low in cost &
- Lower flow rates for good shielding
- Easier arc starting
Welding gas
• Argon mixtures (suitable for
bodywork):
- 95% argon & 5% CO2 and/or
- 80% argon & 20% CO2
- For smoother results
- Better & cleaner spatter free weld
- Improve metal transfer & weld finish
- Used on HSS
Welding gas
• Carbon Dioxide (CO2):
- Not an inert gas (passing through the arc
causes breakdown into carbon monoxide
& oxygen)
- Heater is used to prevent freezing of the
gas regulator (after prolonged use)
Welding wire
• Availability:
- 0.6, 0.8, 1.0mm
- 5-15kg
- Coated for rust prevention & to improve
electrical contact
• Solid wires:
- Most common form used for Body repairs
• Cord wires:
- Suitable for thicknesses more than 6mm
Welding Equipment
Short Circuit Arc Welding
Tip to Base Metal
Contact Tip
Nozzle
Tip to Base metal
Distance
8 ~15 mm
Wire Protrusion Length

Tip to Base
Wire
Metal
Arc
Tip-base metal distance

Welding Conditions
Welding Current
Relationship Between Wire Diameter, Panel
Thickness, and Welding Current
Arc Voltage and Bead Shape
MIG/MAG Welding
process
Tack welding
MIG/MAG Welding process
Butt welding
MIG/MAG Welding
process
Welding points
MIG/MAG Welding
process
Plug welding a damaged panel
Welding positions
Method
• Drawing method: Torch slopped in
direction of weld
• Thrusting method: Torch slopped

away from direction of weld
Welding positions
Forehand Backhand
(Thrusting Method) (Drawing Method)

Welding positions
Welding stress
& distortion
Common problems:
• Residual stress & distortion
• Incorrect bead geometry &
appearance
• Defects
• Loss of properties
Minimizing distortion
Minimizing distortion
Weld defects
INSUFFICIENT PENETRATION
Weld defects
Excess weld spatter
Weld defects
IRREGULAR BEAD SHAPE
Weld defects
BURN THROUGH
Thank you
for your
attention

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Body Instructor Course Step 1

TOYOTA MOTOR CORPORATION

Carbon Dioxide arc welding

(3) Braze Welding Hard Brazing (brass)

2. Brazing must not be performed at areas other than those

3. Oxy-acetylene welding must not be used.

3. It does not require much skill or experience.

4. Due to the large electrical current required,

• To conduct the current to the weld area

• Metal inert gas (MIG) welding

• Metal active gas (MAG) welding

Wire Protrusion Length

Tip-base metal distance

• Thrusting method: Torch slopped

(Thrusting Method) (Drawing Method)

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