Mitsubishi Outlander XL. Manual - part 38

 

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Mitsubishi Outlander XL. Manual - part 38

 

 

ZB600206

15 – 30°

15 – 30°

Forehand
technique

Backhand
technique

0000

The angle of the torch should be 15 - 30 degree angle for either
technique, and the tip should be maintained at a distance of 6 -
10 mm (0.2 - 0.4 inch) from the surface being welded.

 

Preventing warping

ZB6002070000

Anti-warp welding techniques

1.

2.

3.

Backhand technique

Symmetrical technique

"Stepping stone" technique

5

4

3

2

1

5

4

3

2

1

4

3

2

1

1.

Backhand technique
Because  the  direction  for  each  weld  pass  and  that  for  the
fusion progression are opposite, the residual stress is evenly
distributed.

2.

Symmetrical technique
Because  the  welds  are  made  in  symmetrical  positions  in
relation to the center of the joint, the residual stress is also
symmetrical.

3.

"Stepping stone" technique
Because  the  welds  are  made  at  random  positions,  the
residual stress is the most evenly distributed; however, the
possibility  of  flaws  at  the  starting  and  stopping  points  is
relatively high.

NOTES REGARDING MIG WELDING

Note the following notes regarding MIG welding.

1.

The surface to be welded must be perfectly clean;
be sure to remove any non-conductive paint.

2.

If  the  end  of  the  wire  forms  into  a  ball,  it  will
adversely affect the formation of the arc; cut the
end off with a pair of wire snips or a similar tool.

3.

Select a welding current to match the thickness of
the panels being welded.

4.

For continuous welding, maintain a constant weld
speed and keep both the height and the width of
the bead constant.
In addition, the tack welding pitch and the welding
bead  should  be  shorter  as  the  thickness  of  the
panels being welded decreases.

OTHER TYPES OF WELDING

M40900000040USA0000010000

BRAZING

In brazing, a filler metal is melted into the joint of the
panels  to  be  welded  at  a  comparatively  low
temperature to fuse them together without melting the
panels themselves. In other words, through the aid of
a flux and because of the capillarity phenomenon, the
molten filler metal will flow into the joint between the
two panels which are in contact with each other and
spread  along  the  metal  surfaces.  When  this  molten
filler metal cools and solidifies, it will from a strong joint
of the two panels. Note that, if two panels of different
kinds of metal are brazed, the electrolysis generated

between the two metals will cause moisture to from,
which will result in corrosion.
Panels should not be connected together by brazing
at  any  place  except  those  places  indicated.  The
following materials (filler metals) are usually used for
brazing.

1.

Brass filler metal (brass solder)
Brass  filler  metal  is  an  alloy  consisting  of  60%
copper and 40% zinc with a melting temperature
of approximately 850 - 1,050°C (1,562 - 1,922°F),
and  it  is  the  most  commonly  used  brazing  filler
metal used for body repair.

BASE OF BODY REPAIR

9-11

WELDING

The filler metal itself is coated with flux to facilitate
penetration between the panels to be joined.

2.

Silver alloy filler metal (silver solder)

Silver alloy filler metal consists of silver, copper,
zinc or cadmium, nickel, and tin, or other metals.
This filler metal is most applicable for the brazing
of steel and non-ferrous alloy other than aluminum,
magnesium, and others with low melting points.

 

Notes with regard to brazing work

ZB600208

Examples of brazed joints

0000

Use a wire brush, sandpaper, file etc., to remove
any oxide film grease, dirt, etc., from the surfaces
of the panels to be brazed.

When  doing  brass  brazing,  if  the  panels  and  the
filler  metal  are  heated  excessively,  a  weak  iron-
copper alloy will form, which could crack easily. Be
careful not to apply excessive heat.

The joint of the panels must overlap as indicated in
the illustration.

GAS WELDING

ZB600209

Deposite

Base metal

Welding
rod

Oxy-acetylene
flame

0000

Gas welding is a method in which a high temperature flame is
used to melt both a welding rod and the base metal (panels) to
make a fused joint. Oxy-acetylene is the most common type of
gas  welding.  However,  because  of  the  extremely  high
temperature  of  the  fused  joint,  the  strength  of  the  steel  plate
deteriorates, and there is a higher possibility of warping. This
method, therefore, is not very suitable for body repair.

The flame in gas welding can be classified according
to the ratio of acetylene and oxygen.

9-12

BASE OF BODY REPAIR

WELDING

ZB600210 

Flame core

Outer flame

Acetylene cone

0000

1. Carburizing flame

Outer flame

Outer flame

Flame core

Flame core

2. Standard flame

3. Peroxide flame

1.

Carburizing flame (acetylene-rich flame)
This  flame  has  an  excess  of  acetylene  or  a
deficiency of oxygen. The incomplete combustion
gives off a black smoke, and two flame cores can
be  seen  inside  the  deformed  yellow  flame.  The
flame  itself  is  large,  but  the  temperature  is
relatively  low,  making  this  flame  unsuitable  for
welding.

2.

Standard flame (neutral-mixture flame)
This  flame  has  approximately  equal  amounts  of
acetylene and oxygen. The length is shorter than
that  of  the  carburizing  flame;  the  flame  core  is
rounded; and it is clear and bright.
The carbon in the acetylene is burned completely,
resulting in the maximum obtainable temperature.
This is the flame most commonly used for welding.

3.

Peroxide flame (oxygen-rich flame)
This flame has an excess of oxygen or a deficiency
of  acetylene.  The  flame  core  is  shorter  and
sharper,  and  the  entire  flame  has  a  blackish-

purplish color. The combustion is unstable, and the
flame flickers continuously.

Notes with regard to gas welding

1.

Handle the oxygen and acetylene tanks carefully.

2.

Adjust  the  flame  in  accordance  with  the  type  of
metal being welded.

3.

Select  a  nozzle  to  match  the  work  to  be  done.
Avoid overheating and adhesion of foreign matter
(dirt, etc.)

4.

The  following  points  are  particularly  important
when welding mild steel plate.

Melt a sufficient amount of welding rod, but be
careful  not  to  melt  the  base  metal.  Use  the
same amount of welding rod on both sides.

Use  the  correct  amount  of  welding  rod  in
accordance with the melting point of the base
metal.

Avoid  welding  over  places  which  have  been
welded before.

In order to avoid warping, do only the amount
of tack welding that is absolutely required.

BODY REPAIR

STANDARD BODY REPAIR PROCEDURES

M40900000060USA0000010000

The following is an explanation of the standard repair
procedures for the monocoque body and the frame-
type  body.  Furthermore,  please  refer  to  the
replacement  of  welded  panels  for  the  applicable
model for information concerning the procedures for

replacement of panels (as classified by position) for
the various models.

NOTE: 

That reference should be made to

page P.9-27concerning repair procedures for
the frame of frame-type vehicles.

BASE OF BODY REPAIR

9-13

BODY REPAIR

STANDARD PROCEDURES FOR

REPLACEMENT OF WELDED PANELS

In  order  to  maintain  the  proper  levels  of  strength,
rigidity,  and  precision  when  making  welded  panel
replacements, it is essential to first gain a thorough

understanding  of  the  body  structure,  and  then  to
perform all repair operations carefully and correctly.
In addition, when performing the operations, be sure
to  use  the  proper  protective  equipment  for  each
operation.

ZB600211 0000

Select an appropriate location for the cutting operation,
and perform the work carefully, so as not to cut into the
reinforcements  located  inside  the  pillars,  panels  which
are not be replaced, or any other such parts.

There are harnesses, hoses, and other such parts routed
inside the front pillar, the rear pillar, the fender shield, the
side sill, etc.; perform the repair work only after any such
material has been removed.

For overlap cutting, allow an overlap of approximately 30
-  50  mm  (1.2  -  2.0  inches)  when  performing  the  cutting
operation.

1.

Rough cutting of panels
First  make  a  rough  cutting  of  a  portion  of  the  panel  to  be
replaced, and then remove that portion, thus making it easier
to break the spot welds.

ZB6002120000

2.

Removal of the paint coat from spot-welded points
In order to clearly identify the spot-welded points, remove the
paint coat from areas where it is difficult to determine the spot
welds.

ZB6002130000

3.

Cutting and separation of spot-welded points
In  order  to  perform  cutting  and  separation  of  spot-welded
points, use a spot weld cutter which is larger than the size of
the nugget to make a hole only in the panels to be replaced.
When  cutting  and  separating  spot-welded  points  in  places
where the surrounding panel or other parts interfere with the
spot weld cutter, or if the operation is hampered by a lack of
space, bend back the flanges in order to make the work easier.
If a spot-weld cutter cannot be used at all, cut and separate
the spot welds by using a chisel or similar tool.

NOTE: 

If a replacement panel is to be mounted by doing

plug welding from the side of the panel remaining on the
body, either a hole can be made in the panel on the body,
or a hole can be made right through both the panel which
is to remain on the body and the panel to be replaced.

9-14

BASE OF BODY REPAIR

BODY REPAIR

 

 

 

 

 

 

 

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