Weighing welders

March 1, 2021
For shops considering pulling the trigger on a new spot welder, there are a few things to consider.

Ten years ago, when a vehicle came into a collision shop to be repaired, it was a pretty straightforward process. Now, vehicles are manufactured with advanced materials like ultra-high-strength steelaluminum alloys and other lightweight materials. As a result, collision repair equipment, like spot welders, has had to advance as well. 

For shops considering pulling the trigger on a new spot welder, there are a few things to consider. Not only is it important to understand the basics of how they work and what equipment features are important, but a shop should know what maintenance is required for the equipment and what training technicians might need. 

How to select the right spot welder  

In the simplest use case, vehicle manufacturers use squeeze-type resistance spot welding to join the various pieces of a car or truck together. When part of a vehicle’s frame or structure is damaged and needs to be replaced, the technician will use a spot welder to secure that new piece into place 

Because many newer vehicles are made of ultra-high-strength steel, aluminum, and other lightweight materials, it’s good to have an understanding of the types of materials and the types of repairs typically made when evaluating different equipment. Shops should not only select a spot welder for the vehicles they repair today but one that can serve them in the future. 

Today’s welders incorporate advanced features like smart technology, automatic modes, and OEM programming, not to mention features like “C” arms, lighter-weight equipment, and attachmentsAll of these features are designed to allow technicians greater flexibility and efficiency and enable them to make welds in even the most difficult-to-reach spots on a vehicle.   

Finally, do not overlook the value of having technicians demo the welder ahead of time. A newer machine can allow the technicians to make a weld much faster versus older welders, which can be heavier and more difficult to hold and may slow down the work. In addition, giving a shop the chance to test a welder ahead of time provides them with the opportunity to determine what optional arms they may want to get with the new welder, as there can be a variety of optionsIt can also help them better identify the benefits or shortcomings a typical model might have   

Save time and money with technician training  

OEM repair requirements can quickly changeso ongoing training is important when selecting a spot welder. An increasing number of OEMs require specific parameters on the types of welds that should be performed on a particular vehicle when it comes to spot welding. Things like amps, weld timescap use and clamping pressure are often recommended by OEMs. Understanding those requirements should absolutely factor into the purchase decision.  

Shops can work with their equipment distributor to have their technicians properly trained on new equipmentDistributors can also provide valuable insights such as helping to determine which types of programming should be used on the spot welder for what OEMs. With so many factors in play, there is a lot of room for operator error. That’s why it’s important to not only understand the materials being used but how to properly use the equipment.  

Spot welder maintenance and safety requirements  

One of the biggest mistakes that shops make when it comes welding is not properly maintaining the equipmentPerforming regular maintenance checks on welding equipment allows technicians to deliver safe, proper, and efficient welding repairs, as well as maximizes the longevity of the equipment.  

Some regular and ongoing maintenance requirements include changing the coolant out every few years, having an equipment inspection done by the shop’s equipment distributor every two to three years, and performing regular visual inspection of the machine—making sure the welding gun or the equipment’s arms are free from damage and performing as intended.  

The biggest maintenance mistake made when using a spot welder inot cleaning or regularly replacing the welding tips. This is often not done as frequently as it should be and can impact the technician’s ability to perform proper and secure weld.  

In addition to maintenance requirements, welding requires health and safety measures be in place. Welding fumes can consist of particulates and metallic oxides that can cause health damage, so ensuring proper ventilation and fume extraction is important. 

A spot welder that offers flexibility and is easy to use is just the first step in selecting the right equipment. Having the right training and performing regular safety and maintenance checks can serve to reduce the chance of costly mistakes, help keep technicians safe and improve the shop’s productivity.  

About the Author

Mike Croker

Mike Croker is the director of product management at Chief Collision Technology. He is a devoted advisor for various technical school organizations and a national technical committee member with SkillsUSA. Mike uses a hands-on approach in training to serve as an I-CAR instructor and is an ASE subject matter expert for Structural Analysis and Damage Repair. For more information, visit www.chieftechnology.com or email him at [email protected] 

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