Welding Precautions - Dual-Phase Steel

WELDING PRECAUTIONS - DUAL - PHASE STEEL

The correct equipment and settings must be used when welding dual-phase steel. MIG and resistance spot welding are the recommended methods. Surfaces must be clean and free of foreign materials.

ER70-S-6 is the recommended wire specification to use when welding dual-phase steel components.

Recommended gas mixtures are as follows: C02, 92Ar8C02, 84Ar16C02 and 77Ar23C02.

Components made of dual-phase steel should not be heated to straighten or repair. New components should be installed if severely bent or kinked.

Do not use Oxyacetylene equipment to weld dual-phase steel.
- Correct eye protection must be worn.
- The correct protective clothing should always be worn.
- Adequate ventilation must be provided to avoid the accumulation of poisonous gases.
- A test weld should always be carried out on a test sample.
- Use cleaning and abrasive grinding wheels dedicated to the type of materials being welded.
- Follow equipment manufacturer's prescribed procedures and equipment settings for the type of welder being used.
- Disconnect the battery ground cable.
- Disconnect on-vehicle modules and protect them from possible heat damage and electrical currents when welding.
- Corrosion protection needs to be restored whenever bare metal repairs made.
- Factory spot welds may be substituted with either resistance spot welds or MIG plug welds. Spot/plug welds should equal factory welds in both location and quantity. Do not place a new spot weld directly over an original weld location. Plug weld hole should equal 8 mm (0.31 in) diameter.
- Vehicles equipped with optional safety canopy require removal of these components prior to any welding procedures being carried out in the roofline or body side areas of the vehicle. Refer to Air Bag Systems.
- Vehicles built prior to 01/2007 contain dual-phase steel in the rocker reinforcement and underbody crossbraces. Vehicles built after 01/2007 contain high-strength steel in the rocker reinforcement and underbody crossbraces.