When weld results are not as desired, we often at our welding equipment. More often than not, this can be an easy fix by adjusting your settings. See below how gas flow can make a difference in your weld results.
The Gas Flow is Too High:
You will see spatter around the weld bead.
It will also cause Inconsistency in the bead height due to the gas pressure being pushed into the bead.
When The Gas Flow Is Too Low:
It will cause the weld to look too porous (If you look closely, you can see the porosity and the pin holes in the weld).
If There Is No Gas Flow:
It causes Inconsistent Feed, spatter and no penetration
It is nearly impossible to weld with.
Incorrect Gas:
This can cause the weld to look like the welding wire is piercing through and cutting the material.
It will look like little pellets dropping on the material.
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With the extensive use of aluminum in vehicle production, aluminum repair is becoming much more common for the average collision repair technician. With this comes the challenge of being able to properly repair and weld these types of panels.
One of the main challenges has to do with the alloy of aluminum that was used by the vehicle manufacturer. Using the same alloy in the repair process as the material you're working on is critical to the success of the repair. Different OEMs use different alloys in their vehicles.
Example: The aluminum series utilized by Ford is different from the alloy used by Tesla or BMW- this can be applied to weld keys as well as welding wire.
Because of these differences, using the correct aluminum key is necessary to ensure a strong hold point and to maintain the integrity of the aluminum.
Pro Spot provides 2 different aluminum keys:
Standard AlMg Key (Aluminum Magnesium)- Ford is a great example of an application where you would want this key. Pro Spot Part #: 50-0012
The AlSi Key (Aluminum with Silicon additive)- This key has a silicon additive- Tesla is an example of an application where these keys would be used. Pro Spot Part #: 50-0014
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MIG brazing is an adhesion process that uses the melted filler metal to adhere to the base material. This differs from MIG welding in that MIG welding is a fusion process, melting the filler metal and the base material together.
OEM Application Examples:
Honda uses MIG brazing in many areas when working with UHSS and HSS steels.
GM uses MIG brazing on newer Chevy Colorado and GMC Canyon aprons where it attaches to the hinge pillar.
Toyota uses MIG brazing in non structural application such as Camry decklid.
Jaguar Land Rover uses a lot of MIG brazing in areas with HSS and UHSS steels.
Why Do Technicians Like This Process?
MIG Brazing is becoming more popular among technicians because the process makes it easy to dress welds and it's quite simple to learn.
This Week's Tech Tip Focuses on Easy Steps to Prevent Breaking HD Dies...
We still receive calls regarding HD dies (PRR-10HD & PRR-11HD) breaking, and the cause is almost always due to the alignment. These dies were designed for rivet removal on thicker stacks of material. Although they are heavy duty, if not used properly they may still fail during removal. It is imperative that the proper steps are followed to ensure a clean and correct removal. Ensuring Correct Alignment on the Backside of an SPR During Removal with the PR-5 Riveter is Essential!
Important To Know:
Before using these dies, be sure to seek proper training from your local Pro Spot representative.
These new HD dies will ONLY work on the newer generation PR-5 or the Upgraded PR-5 models (with the interchangeable arms). These dies will not fit on the original riveter arm.
The existing PRR-10 and PRR-11 dies still work on the original PR-5.
When replacing the PRR-10 with the new PRR-10HD, you must also include the PRR-11HD. Do not combine the two styles of die sets.
Be sure to remove the PRR-Ext 25 or PRR-EXT 30 extension die before using the new PRR-10HD and PRR-11HD
These dies were developed to easily remove SPRs, particularly ones installed in thicker stack-ups of material.
The PRR-10HD has a larger diameter which assists in removing hollow thru-hole SPRs typically used on thicker material stacks.
The die also includes a spring, which aids in two ways:
The spring force retracts after the removal process to avoid making a larger hole in the material.
The spring also helps to center and secure around the rivet for accurate removal.
PRR-10HD and PRR-11HD Rivet Removal Applications include SPR (Standard) and SPR (Hollow thru-hole).
Do not use the PRR-10HD and PRR-11HD to remove the following: Flow Form Rivet, Solid Rivet, Blind/Pop Rivet.
Need More Info? Watch These Tutorial Videos
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When weld results are not as desired, we often at our welding equipment. More often than not, this can be an easy fix by adjusting your settings. See below how gas flow can make a difference in your weld results.
