ASE B3 - Welding, Cutting And Removal

Weldable Materials

Materials suitable for welding in vehicle construction

Non-Weldable Materials

Materials unsuitable for welding in vehicle construction

Gas Metal Arc Welding (GMAW)

Also known as Metal Inert Gas (MIG) welding, minimizes heat buildup

Shielded Metal Arc Welding

Commonly known as 'Stick arc welding', used on thick metals

Plasma Arc Cutting

Method for fast cutting with minimal heat distortion

HSS (High-Strength, Low-Alloy) Steels

Steel type used in vehicle construction, sensitive to heat

MIG Welder

Recommended for welding all vehicle steel types

Oxyacetylene Welding

Not recommended due to excessive heat for welding steel

Welding Safety

Precautions to prevent injuries during welding operations

Arc Flash

Serious injury risk from welding; use appropriate eye protection

MIG Brazing

Alternative to traditional MIG welding, causes less damage

Gas Tungsten Arc Welding (GTAW)

Also known as Tungsten Inert Gas (TIG) welding, used for stainless steel and aluminum

Plug Weld

Common method for joining two pieces of steel in body repairs

Fillet Weld

Type of weld used in body repairs for smooth joints

Butt Joint

Welding joint where two pieces of steel are beveled and backed

Electrode Wire

Comes in various sizes and chemical compositions for welding

AWS Code

American Welding Society code for wire identification

ER70S-6

Wire with AWS code for best quality welds on mild steel and HSS

Flux-Cored Wire

Wire with flux core for shielding gas protection in welding

Wire Feed Speed

Adjustable speed matching heat setting for smooth welds

Polarity

Setting affecting weld penetration, can be straight or reverse

Electrode Stickout

Distance affecting wire melting speed and penetration

Gun Angle

Angle of the welding gun relative to work piece and travel direction

Travel Speed

Speed determined by wire speed and heat for weld quality

Stitch or Pulse Setting

Setting for intermittent welding to cool between welds

Skip Welding Technique

Method of making short weld lengths to prevent heat buildup

Resistance Spot Welding

Electric welding method using pressure, current, and time for weld nugget

Resistance Spot Welding (STRSW)

Uses short weld time, minimal heat affected zone, and reduced risk of warping.

Galvanized Coatings

Preserved better with STRSW due to less heat application.

Weld Nugget

Result of current flow between electrode tips in resistance spot welding.

Welding Arms

Must have proper angle and alignment, dressed periodically, and allowed to cool.

Weld Through Primer

Applied sparingly to bare metal before welding.

Oxyacetylene Cutting

Cutting method using oxygen and acetylene, not recommended due to heat.

Brazing Rods

Used in oxyacetylene brazing, can be flux-coated or bare.

Weld Bonding

Method using structural adhesives with STRSW for superior bond.

Skip Welding

Technique for long joints on thin metal to prevent warping.

MIG Welder Controls

Adjust voltage and wire speed for penetration and porosity control.

Weld Penetration

Affected by electrode stick out length in welding.

Resistance Spot Weld Tuning

Adjusting welder settings for material thickness.