Mastering welding: Ensuring safety, quality, and OEM compliance

Welding is a process that has evolved significantly in our industry over the decades, with advancements in weld types, equipment, machinery, processes, and substrates. However, the need for a quality weld that performs reliably remains unchanged. Despite the passage of time, it's surprising how many individuals still struggle with achieving this standard. At the 3M Skills Development Center, I observe this challenge weekly. A common underlying issue is a lack of understanding of the fundamental basics, which leads to many of these difficulties. 

I emphasize this point in every class: if a vehicle is not deemed a total loss, your responsibility is to repair it so that it can safely return to the road, capable of withstanding similar or even more severe accidents while managing crash energy as originally designed. Customers expect this level of safety when they pick up their repaired vehicle. During recalibration, the vehicle's systems assume that all repairs and welds meet specific standards. There is no "Oops" button to account for poor penetration, lack of fusion, or any weld imperfections that could alter the performance or timing of the vehicle's safety systems in a future accident. So, how can you ensure that you've done the job correctly? 

To optimize your welding operations, it's essential to have a deep understanding of your equipment's functionality and maintenance requirements. This includes ensuring the equipment receives the correct power supply, understanding how different settings and adjustments affect the welding process, and developing a comprehensive standard operating procedure for storage and maintenance. Since most equipment is shared within the shop, a well-defined SOP is vital for maintaining consistency, extending the equipment's lifespan, and ensuring peak performance. 

Have you ever wished for a guide that provides precise instructions for achieving faster and, more importantly, correct welding results on vehicles? original equipment manufacturers have specific requirements for panel prep, welding equipment, wire, gas, and settings. While this information may not be included in the repair procedure, it can often be found in position statements. These statements may apply to all makes and models or just one, making it essential to review them for every repair. A simple search for "welding" or "welding conditions" during the research and planning phase will likely lead you to the necessary information on approved equipment and setup. This includes the types of welds based on materials, material thickness, locations, shielding gas, and other joining considerations. There is no "general rule" that suffices for all makes and models. Many OEMs also mandate destructive test welds for every type of weld being made. However, compliance with these requirements is often inconsistent. Technicians frequently skip these critical steps, sometimes citing reasons like "It's not on the estimate," or "They didn't pay for that." This mindset can compromise the integrity of the welds and, ultimately, the safety and reliability of the repairs. 

One of the most frustrating practices I observe in shops is when a technician makes a weld, sets the welder down, grinds the weld, then picks up the welder to make another weld followed by more grinding. This is the number-one indicator of poor welds being made. Technicians are aware of this and quickly grind the welds to conceal the issue. It's also an inefficient way to attach a new panel, often resulting from not taking the time to properly set up the welder and perform test welds, both of which are non-included operations required by the OEM to ensure weld quality. How else will you know if you have penetration on a butt joint if there's no access to the back to see? And even if you did, once the weld is made and it's not right, what is your next step? 

Let's be honest, even when all guidelines are followed, accountability remains a significant challenge. As a trainer at 3M, it is my responsibility to provide education to our students on the best practices, procedures, and requirements available. However, I believe that shops should establish a process for accountability, especially for such a critical aspect of the repair, to ensure it is done correctly. Practice coupons and proper documentation are often sufficient, but if these are not captured accurately, who is responsible? Who will oversee this process in the shop to ensure that when we return the vehicle, the repairs — or welds, in this case — are completed properly? 

Whoever is tasked with this responsibility should be included in the welding training that shops provide for their technicians. This training could be offered by equipment manufacturers, the OEM, or another certified third party capable of administering both hands-on and knowledge-based testing. Comprehensive training ensures that the shop and those responsible for repairs can distinguish between correct and incorrect practices. It also equips them with the skills to make necessary corrections or document processes accurately, thereby maintaining the shop's cycle time and ensuring high-quality repairs. Investing in thorough training not only enhances the skill set of the technicians but also reinforces a culture of accountability and excellence within the shop. Enhancing welding practices is crucial for ensuring the overall quality and safety of repairs in our industry. By recognizing the importance of proper welding techniques and strictly adhering to OEM requirements, we can significantly minimize the occurrence of substandard welds. So, what is the straightforward solution? 

1. Adhere to OEM Guidelines:  Ensure that all welding equipment, materials, and settings are in full compliance with OEM specifications to maintain consistency and quality. 
2. Educate Technicians:  Provide comprehensive training on welding techniques and emphasize the importance of following OEM guidelines to equip technicians with the necessary skills and knowledge.
3. Conduct Destructive Tests:  Regularly perform destructive test welds to assess and validate the quality and strength of the welds, ensuring they meet industry standards.
Implement Inspections:  Establish a rigorous inspection process to verify the quality of welds before they advance to the next stage, ensuring that only high-quality repairs are completed. 

By focusing on these key areas, we can elevate the standards of welding practices, leading to safer and more reliable vehicle repairs.