TECH TIP: Destructive Testing 101

Tuesday, July 31, 2018

Destructive Testing 101


The Importance of Destructive Testing 
& Performing Tests in the Shop. 
With the advanced materials being used during vehicle production such as HSS and UHSS, destructive testing is a must in the collision repair industry to ensure proper and safe repairs.

Whether we are using Resistance Spot Welding or MIG/Mag welding, we must perform a destructive test before welding on the actual application. This helps ensure that the weld settings are correct and the welder is functioning properly. 


How to Perform a Destructive Test:

Click here to watch video 

In the shop, we have two destructive tests: Twist Test and Peel Test. Which test is best to perform depends on the type of weld being done and the material used. 

The Peel Test is best performed on a resistance spot weld (see image below).

  • This test done by clamping the test material in the vice and peeling the top layer from bottom using rounded end channel locks.
  • With this test we should see the weld nugget stay in tact while tearing a hole in one of the layers. 
    • The "Twist test" uses a vice and a hammer. Using the hammer hit up and down on sample "twisting" the weld until it comes apart.
  • NOTE: This test may be harder to complete on HSS and UHSS

The Twist Test this can be done on resistance spot welds or plug welds. 































    • This test is performed by clamping one layer in the vice and twisting top layer from bottom.
    • Using the hammer hit up and down on sample "twisting" the weld until it comes apart. 
    • With this test we should tear a hole from one of the layers for a successful test. 
    • NOTE: According to I-CAR standards: On an 8mm Plug Weld, a 5-10mm hole should tear out from bottom coupon depending on the material and stack up.


    Follow us on Social Media for news, product info and more...

    Twitter

    Facebook
    Website
    Instagram

    For more Tech Tips and Videos, visit our YouTube Channel and subscribe to stay updated! 
    YouTube


    Leave a Comment ,

    TECH TIP: SP MIG 'Hot Start': The Why & How!

    Tuesday, July 24, 2018

    SP MIG 'Hot Start': The Why & How!

    The Benefits & Programming of the SP Pulse MIG Welder's Hot Start Function.

    Quick Overview

    It's no secret that welding aluminum is different than steel. One of the biggest differences is how heat is dissipated on aluminum.

    • Steel: Heat stays confined to the area where the heat is applied.

    • Aluminum: Heat rapidly transfers throughout the material. 

    This causes what is known as a "Cold Start";  the beginning of the weld bead is weak due to not enough heat at the start causing poor penetration. To counter this we have two options: 
    1. Tail-In Method- You start the weld outside and move in toward the weld join so that the material is pre-heated allowing proper penetration. 
    2. Hot Start function - The cleanest way to program it and avoid the cold start. (See VIDEO below)

    Solution: 

    The SP series MIG welder's "Hot Start Function", allows us to dial up the amperage at the start of the weld for a set amount of time, ensuring proper penetration.

    HOW TO ADJUST HOT START
    SP-1, SP-2, SP-5:
    1. Access the Set-up Menu

    2. Using the "SETUP" button, scroll until you see "Hot Start %".


    HOW TO ADJUST HOT START
     SP-5.3 & SP-5.1DP:
    1. Access the Set-up Menu

    2. CYCLE must be on "Full".

    3. Using the 'Down Arrow', scroll through settings until you see "Hot Start %". 
    Hot Start Variables
     SP-5.3 and the SP-5.1DP:

    1. Hot Start % this shows as a % that will be the percentage over 100, indicating how high you want the Hot Start to be.
    2. Hot Start V. gives us the ability to widen or narrow out the weld bead for the set Hot Start. 
    3. Hot [Start] Slope time, the time that it takes to go from the Hot Start setting back to original welding parameter.

    4. Hot Start Time is the actual time in seconds below that indicates the amount of time the Hot  Start will last before returning to 100%. 

     Watch this video for a closer look at How to Set Up the Hot Start Function 




    Follow us on Social Media for news, product info and more...

    Twitter

    Facebook
    Website
    Instagram

    For more Tech Tips and Videos, visit our YouTube Channel and subscribe to stay updated! 

    YouTube


      






    Leave a Comment ,

    TECH TIP : LOCKTITE FOR LINER

    Tuesday, July 17, 2018



    Two Piece Aluminum Liner Giving You Trouble?


    Don't Blame the Welder! This Tech Tip Will Help You Keep It Together...



    Aluminum Liner Facts:
    • With concern of corrosion and Aluminum being a softer wire than steel -  a smooth feed through the torch is a MUST if you want consistent weld quality.
    • The Aluminum Liner is made up of two materials (graphite and upper steel section) that screw together to guide the wire through the torch neck. 
    What Can Happen:
    • If the two halves separate, it causes poor feeding, inconsistent welds, damaged wire, and excess time spent diagnosing the problem or blaming the welder - all of which is wasting productivity.
    PRO TIP: 
    • During new set up, or replacing an aluminum liner- add a dab of Loctite to the steel end-threaded to the graphite. This ensures the liner will not come apart.
    • Spare yourself (and your welders) the frustrations of troubleshooting. Utilize this tip and eliminate wasting time and resources

    Follow us on Social Media for news, product info and more...

    Twitter

    Facebook
    Website
    Instagram

    For more Tech Tips and Videos, visit our YouTube Channel and subscribe to stay updated! 

    YouTube


      

    Leave a Comment ,

    TECH TIP: What's Your Squeeze Pressure?

    Tuesday, July 3, 2018

    What is your Max Squeeze Pressure: 

     Squeeze Chart Showing Pressure based on PSI and Force on the Pro Spot Weld Guns: 

    PS-500 (Blue) & PS-600W (Black)



     Quick Reference: Understand the Difference Between What Is Best & And What Is Required To Meet OEM Requirements.

    Following vehicle manufacturer repair instructions is a MUST in today's collision repair industry. In many cases, this goes as far as - the available air pressure, the power and tip force requirements that are needed in order to properly repair vehicles. By following these instructions, you're making sure the equipment being used is capable of doing such repairs properly and safely.

    Example of an OEM requirement: Honda specifies that a resistance welder must meet or exceed 9,000 amps and 772 lbs. of tip force or pressure. 

    Below is a quick reference chart showing the difference in squeeze compression at different inlet air pressures. 60-135 PSI. 

    NOTE: Supply of air pressure may also play a role; especially for higher air pressures needed. 
    Example: A weld gun needing 135 PSI to reach 790 lbs., needs consistent pressure at the time of the weld to ensure requirements are met. 


    Pictured above: Graph showing PS-500 V.S PS-600 gun squeeze pressure

    Follow us on Social Media for news, product info and more...

    Twitter

    Facebook
    Website
    Instagram

    For more Tech Tips and Videos, visit our YouTube Channel and subscribe to stay updated! 

    YouTube






    Leave a Comment , ,
    Powered by Blogger.

    Copyright BETA Pro Spot. Designed by Georgia Lou Studios

    Back to Top