PRESENTED BY:

TOBY CHESS & KYE YEUNG

Technical PresentationDestructive Weld Testing

What kind of music do welders like?Answer--Heavy Metal

Destructive Testing using Squeeze Type Resistance Welders

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Crash Test Using Acura approved OEM procedures VS non approved procedures

Acura Approved OEMRepair Procedures

Non OEM RepairProcedures

Collision Repair HeadlinesJuly 17, 2018—An Ohio appellate court on Friday rejected an auto body shop's arguments in a $105,462 case where the body shop was convicted for failing to follow OEM procedures during a repair.

Dallas Body Shop Ordered to Pay 31.5 Million for not following OEM Procedures

A Major MSO. with 38 collision repair centers, has settled a ... had collision repairs performed that did not followmanufacturer procedures.

What Ford states about destructive weld testing

What Toyota states about STRSWdestructive testing

Audi’s Position Statement on STRSW destructive testing

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Nissan’s Position Statement on STRSWW destructive testing

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Honda’s Position Statement on Destructive STRSW testing

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Steps for conducting adestructive weld testusing a Squeeze Type Resistance Spot Welder

•Cut 2 pieces of damaged sheet or any excess sheet metal from replacement part• Follow OEM procedures on test coupons that are going to be used in the repair process.•Prepare the coupons where the STRSW electrodes will make contact.•If you are using adhesive a shunt pliers will be necessary for the destructive test•If you are leaving the E-coat in place, it will be necessary touse a shunt clamp

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Peel Test Procedures for destructive Testing

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•Measure the thickness of each of the two (three) coupons•If two different thicknesses of sheet metal is used, add bothpieces together and divide by 2to get the test thickness

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Peel Test Procedures for destructive Testing

•Clamp the two testcoupons together leavinga ½ inch overlap•Make sure the clampsare isolated (black electricaltape).

Peel Test Procedures for destructive Testing

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•Place a spot weld in the center of the coupon and 1 inch from the edge of thebottom coupon

Peel Test Procedures for destructive Testing

•Roll the V-Jaw pliers into each other ( note the position of each pliers)

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Peel Test Procedures for destructive Testing

•Peel back the coupons to expose the weld nugget tear out.

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Peel Test Procedures for destructive Testing

•Measure the diameter of the tear out. In this example the least amount of the diameter tear out was 5.25 MM.•A good formula is 5 times the thickness of the sheet metal, but always consult the OEM procedures.•Metal thickness is .8MM time 5 equals a min. tear out of 4.0mm

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Peel Test Procedures for destructive Testing

•Show peel test results with caliper, RO#, Date and Technician on coupon.•Photo and attach to file

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What is the destructive procedure for weld bonding & E-coat between the mating surfaces

Shunt Pliers

E-Coated metal coupons

What is the destructive procedure for weld bonding & E-coat between the mating surfaces

Cut two pieces of E-coated coupons from the vehicle and attach shunt pliers. Cleaned two locations on

the outside of both coupons; one for

the shunt pliers to make contact and the other for the

electrodes.

What is the destructive procedure for weld bonding & E-coat between the mating surfaces

Note that the vice grip pliers where taped with electrical tape to prevent the pliers from acting like a poor shunt. A resistance spot weld was placed on the

clean part of the coupon. The E-coat is left intact between the two mating surfaces.

Destructive MIG Welding Tests

6MM Plug Visual Inspection

Results of 6MM Destructive Test

Failed Destructive Test Passed Destructive Test

Hole Diameterwas 2MM

8mm plug-Passed Visual Inspections

8MM Plug welds that failed Visual Inspections

8MM Destructive Tested Welds

Failed Destructive Test Passed Destructive Test

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