Mitsubishi Outlander XL. Manual — part 38

ZB600206

15 – 30°

15 – 30°

Forehand
technique

Backhand
technique

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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

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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

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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

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Examples of brazed joints

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｠

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

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Deposite

Base metal

Welding
rod

Oxy-acetylene
flame

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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

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Flame core

Outer flame

Acetylene cone

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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

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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.

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｠

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.

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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.

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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