Ford Galaxy / Ford S-MAX. Manual — part 1015

Special features to note during bead welding:

Both parts of the panel must be bare on both sides over a width of 5 mm.
Align the parts precisely with clamps.
To prevent the panel from warping, tack longer joints before welding them.

Intermittent bead welding

Intermittent bead welding is used when the connecting flanges are stepped. This form of
seam is mainly used on the external panel area for sectional repairs.

Special features to note when intermittent bead welding:

Weld gap.
Spot weld interval.
Apply alternate tack welding across the entire length of the seam. This keeps warping to
a minimum.

MIG brazes

Metal Inert Gas (MIG) brazing is increasingly used in production for certain body areas.

In areas where resistance spot welding is not possible due to limited space or higher
strength requirements, MIG welding was previously used.

Increasingly, these MIG welded seams are being replaced by MIG brazes. The temperature
range used during MIG brazing is significantly lower. This keeps the damage to the anti-
corrosion zinc layer on zinc-coated panels to a minimum.

This results in the following advantages of the MIG brazed seam:

No corrosion of the brazed seam.
Low erosion of the zinc coating in the joining area.
Low level of heating and thus little warping.
Easy finishing of the brazed seam.
Good for bridging gaps.

NOTE: MIG welds must not be carried out on or near existing MIG brazed seams as even
the smallest amount of brazing solder can result in a reduction in the strength of the weld
seam.

MIG brazing requires a new generation of welding equipment and training in the technique.

Joining techniques

Description

Description

1

Rear side member / wheelhouse reinforcement

2

Apron panel reinforcement / A-pillar

Butt joints

The butt joint is a joining technique frequently used in body repairs. The butt joint is
typically used for repairs in the pillar and rocker panel area.

Areas that are suitable for the use of the butt joint:

short seam lengths.
highly profiled structures.

The edges of the panels to be joined are placed against each other and are joined with a
full seam in whilst maintaining a required welding gap (welding gap same as panel
thickness).

NOTE: The butt joint requires a high degree of accuracy and care when trimming and
cutting. For correct execution of the welding, an exact, even welding gap must be
maintained.

Preparation of the joint areas includes:

Sanding the connection areas bare on both sides.
Removal of the zinc layer in the welding area.
Carrying out welding tests on an equivalent sample panel before the actual welding, if
necessary.
Tack welding in the join area: From the edges to the centre, then check the shape.
Joining new and old parts with a full seam weld.

Joggled joint

Description

Description

1

Join areas

2

Profile

3

Full seam

The joggled joint variant is restricted to body areas with a good surface condition without
beads/swage lines or profiles. A sectional replacement with a joggled joint is welded using a
continuous seam. This procedure is used, for example, at the transition from the side panel
to the rocker panel (3-door vehicles).

When cutting the new part, slight measuring tolerances are permitted, as these are covered
by the joggled area.

Preparation of the joint areas includes:

Sanding the connection areas bare on both sides.
Removal of the zinc layer in the welding area.
Preparation of a joggled strip.
Carrying out welding tests on an equivalent sample panel before the actual welding, if
necessary.
Joining the new and old panel with continuous seam welding.
Lead loading the weld seam.

Soft soldering

WARNING: The roof repair may only be carried out in Ford-approved special

workshops and only by specially trained personnel.
NOTE: The roof is secured to the side walls with laser soldered seams in production.
When repairs are carried out, these laser-soldered seams must be replaced by soft-
soldered seams.

WARNING: Poisonous gases and dust can be produced when working solder. Use an

extraction unit and, if required, a protective mask.
NOTE: Ford offers basic and in-depth training on the following topics.
NOTE: Areas for soft soldered joints require careful preparation. It is extremely important
that the joint surfaces are exactly aligned and that a bare metal joint surface is prepared.

Description

Description

1

Body part

2

Joggled area

3

New panel