# WORK NOTICES AND PRECAUTIONS > PRECAUTIONS FOR WELDING

REMOVAL OF ADJACENT COMPONENTS

1. To prevent damage to the body and parts, apply protective tape to the body and tools before removing the parts.

   NOTICE:
     If the paint film is damaged, make sure to refinish the paint.

ANTI-RUST TREATMENT BEFORE WELDING

1. Apply welding primer to the contact surfaces of the welding areas to protect them from rust.

   NOTICE:
     Do not apply welding primer outside of the contact surfaces.

WELDING WORK

1. Follow the welding conditions below when welding ultra high strength steel to assure sufficient weld strength.

   Text in Illustration
   *1 | 980 MPa Ultra High Strength Steel

   When welding 2 panels together including 980 MPa ultra high strength steel.
   Spot weld | Pressure | 2940 N (300 kgf, 661 lbf)
   Weld current | 10000 A
   Weld time | 16 Cyc. (0.27 Sec.)
   Plug weld | Plug diameter | 10 mm (0.39 in.)
   Wire type | AWS A5.18 ER70S-3
   Shield gas | Metal active gas

   NOTICE:
     Be sure to use Metal active gas (Ar 80% + CO2 20%) as the shield gas when plug welding. Sufficient weld strength cannot be assured when using 100% CO2 shield gas.

   Text in Illustration
   *2 | 980 MPa Ultra High Strength Steel

   When welding more than 3 panels together including 980 MPa ultra high strength steel. (When welding a third panel to two panels which are welded under the conditions described above.)
   Plug weld | Plug diameter | Same as the standard method (See the introduction)
   Wire type | AWS A5.18 ER70S-3
   Shield gas | Metal active gas

   NOTICE:
     Be sure to use Metal active gas (Ar 80% + CO2 20%) as the shield gas when plug welding. Sufficient weld strength cannot be assured when using 100% CO2 shield gas.

2. Standard Number of Welds

   980 MPa ultra high strength steel | Number of spot welds | More than the number of welds made by the manufacturer
   Number of plug welds | More than the number of welds made by the manufacturer
   Normal steel or high strength steel | Number of spot welds | More than 1.3x the number of welds made by the manufacturer
   Number of plug welds | More than the number of welds made by the manufacturer

   NOTICE:
     Inspect the welds after spot welding. For points with insufficient weld strength join the panels using plug welds.

3. Spot weld locations

   Text in Illustration
   *1 | Old Spot Locations
   *2 | New Spot Locations

   Avoid welding over previously welded areas.

MAKING HOLES FOR PLUG WELDING

Text in Illustration
*1 | Puncher

1. For areas where a spot welder cannot be used, use a puncher or drill to make holes for plug welding.

   Thickness of welded portion | Diameter of plug hole
   Under 1.0 mm (0.04 in.) | Over 5.0 mm (0.20 in.)
   1.0 to 1.6 mm (0.04 to 0.06 in.) | Over 6.5 mm (0.26 in.)
   1.7 to 2.3 mm (0.07 to 0.09 in.) | Over 8.0 mm (0.31 in.)
   Over 2.4 mm (0.09 in.) | Over 10 mm (0.39 in.)