Body welding: choosing the right equipment and doing the work

Welding body work

Welding is one of the main types of body work. This method is used to carry out the most complex repair of load-bearing elements and strengthening the car body. This article discusses how to cook a car body with your own hands.

Equipment

For the implementation of welding body work, you will need, first of all, a welding machine. According to the design and principle of operation, these devices are divided into three types. One of them is an AC welding machine, also called an electrode machine, the other is a semi-automatic carbon dioxide welding machine, and the third is an inverter.

The device of the first type is not suitable for body welding. This is due to the fact that the welding machine with an electrode is designed to work with metal with a thickness of more than 6 mm, while this parameter of the car body material is from 0.8 to 1 mm.

Therefore, due to the high power, it is possible to burn through the material. Therefore, this tool will not be able to create a high-quality weld. In addition, it is inconvenient to process hard-to-reach places on the car body with an electrode. Therefore, it is unacceptable to cook the body with such a tool. This method is used only occasionally for frame welding.

Welding body work can be carried out with a carbon dioxide semiautomatic device. In addition, with this tool it is much easier to cook the car body than with an inverter. The carbon dioxide semi-automatic machine performs welding with a consumable wire or a tungsten electrode automatically fed into the work area. With this tool, you can weld the metal of the car body with a thickness of 0.8 to 6 mm. In this case, a high-quality, neat weld of great strength is obtained, and there is no stress in the metal around it.

Semi-automatic body welding

In addition, this welding machine provides low consumption of materials. Thanks to the adjustments of the current strength and wire feed speed, you can fine-tune it quite accurately. Non-ferrous metals can also be cooked with a carbon dioxide semiautomatic device. To do this, replace carbon dioxide with argon. In view of this, this type of welding machine is the most widespread among similar devices in car services and garages and is most suitable for do-it-yourself welding.

Inverter application

You can also use an inverter to weld the car body. Usually this tool is used to speed up work. The principle of its operation is based on the use of high frequency currents (30 - 40 kHz, unlike 50 Hz for other welding devices). The inverter is characterized by compactness and high welding speed. This tool has many modes of operation, which helps the performer in mastering. Therefore, the inverter is recommended to cook for novice users. Finally, the device can be used even in a network with reduced voltage.

The disadvantages of the inverter include high cost, sensitivity to dust, the inability to work with metal with a thickness of more than 3 mm. In addition, resistance welding with this tool gives a thick, uneven seam and leads to strong heating of the metal, resulting in the formation of temperature deformations.

As for the technology of work, contact welding with its use is carried out in the same way as with a conventional welding machine. The difference between these devices is constructive, and consists only in the principle of supplying voltage.

inverter welding machine

Training

Before starting welding work, you need to prepare the car body. First of all, it is necessary to clean the treated areas from all contaminants. Further, by grinding, the paint and varnish coating and corrosion are removed from these fragments of the car body. You also need to check the electrical network of the room where it is planned to carry out welding work, whether it can withstand the load of the welding machine.

If the network meets the requirements, the carbon dioxide semiautomatic device must be charged with a welding wire. To do this, you first need to remove the gas nozzle from the burner and unscrew its copper tip with a wrench. Next, set the required polarity of the current, moving aside the pressure roller with the wire. This parameter is determined by the type of wire used. For ordinary wire, a plus is set on the burner, and a minus on the clamp, and vice versa for flux-cored wire. After that, the wire is inserted 10-20 cm into the feed channel and the pressure roller is returned to its original position.

As a result, the wire should be on the leading roller in the hollow, but not crumble. Then the carbon dioxide semiautomatic device is connected to the network and the key on the burner handle is pressed. First, the gas supply begins, then current and wire. Finally, you need to select a copper tip, put it on the wire and install the gas nozzle on the semi-automatic. To better understand how to prepare a carbon dioxide semiautomatic device for work, you can watch the video.

Basic Rules

Welding of the car body can be done by hand with an intermittent or continuous seam. The choice of method is made on the basis of the availability of parts, their thickness and design purpose. Welding with an intermittent seam is relevant on thin sheet metal for elements between which there is a gap in order to avoid burning through them. If body parts are connected closely, they are welded with a continuous seam.

When creating a continuous seam, regardless of which welding machine is used, several steps should be followed. First, the parts to be welded are connected in several places for fixation. After that, several short seams of 1 - 2 cm are made along the connection line. The final connection is made at the final stage. Between these actions take breaks to cool the metal. Contact welding in this way avoids thermal deformations.

Upon completion of the work with your own hands, it is necessary to carry out anti-corrosion treatment of the seam, otherwise there will be a rapid rust damage to this area, and both sides of the seam must be treated.

It should be noted that in the conditions of factory production, spot welding technology is used. This method has significant advantages over garage and service technologies. So, it allows you to avoid the effect of thermal expansion of the metal, eliminate the use of consumables, increase the accuracy of alignment of car body parts. In addition, the parts welded in this way have the possibility of spring deformation, and there is no weld, which is positive from an aesthetic point of view, since the body without it looks much more attractive.

body welding

The essence of this technology is that the parts to be combined are compressed at one of the points by two non-consumable electrodes that pass current. In this case, two layers of tin are fastened at the point of contact. Resistance spot welding does not give a tight connection, but this is compensated by the use of a sealant.

When doing welding with your own hands, this technology is almost never used due to the high complexity and the need for many additional materials. Although, this method is still found in some workshops.

conclusions

To understand which welding method to choose and, consequently, a device for welding on your own, you must first evaluate knowledge in this area. Also, the choice is made on the basis of the goals of body welding. Welding a car body with an inverter should be for inexperienced users, experienced performers should preferably use a carbon dioxide semi-automatic machine, as it provides better quality, and those who wish to achieve factory quality should follow spot welding technology. In any case, you should first watch the video, which can also help you decide.


1 point2 points3 points4 points5 points (1 votes, article rating: 5,00 from 5)
Loading...Loading...