Basic for Automotive Welding Repair

Welding is an essential part of many industries worldwide, including automotive repair and fabrication. Many renowned car-making companies use automated welding processes such as MIG or TIG welding during vehicle manufacturing.

However, you can also use welding at home to repair automotive parts. Repairing or stitching auto body panels, suspension, engine parts, or exhaust can be an exciting hobby or even a lucrative career.

That's why we'll explain the basics of automotive welding repair, including the knowledge, processes, and equipment you'll need to master this technique.

Welding In the Automotive Industry

Welding plays a crucial role in the automotive industry because it ensures the structural integrity and safety of vehicles. Welders and companies use it to join various metal components, such as the car's frame, body panels, and engine parts, to make vehicles more durable and crash-resistant.

In recent years, the automotive industry has turned to lightweight yet strong designs to improve fuel efficiency and performance. That's why we are seeing an increased use of advanced welding techniques that can deal with modern materials like aluminum and high-strength steel.

However, basic automotive welding repair still uses several essential welding techniques such as MIG, TIG, spot, or Stick welding. So, let's see how and in what applications.

Welding Materials in the Automotive Industry

The goal of today's automotive industry is to introduce lightweight and fuel-efficient vehicles. Automotive companies are striving to meet safety and environmental standards, so we are seeing increased use of new metals.

The most common metals used in the automotive industry today are:

• Steel is the most common material, particularly high-strength steel, which offers durability and crash resistance. However, due to their higher weight, types like mild steel and galvanized steel are being replaced whenever possible.
• Advanced High-strength Steel (AHSH): Advanced high-strength steels (AHSS) are alloys that often have very complex and hierarchical microstructures. These sophisticated materials have carefully selected chemical compositions that give them high-strength, low-weight properties.

• Aluminum: Aluminum is becoming increasingly popular in the auto body industry, and car makers are using it in body panels, engine components, chassis, and structural parts. The strength-to-weight ratio and corrosion resistance make aluminum an essential part of the automotive industry.
• Stainless steel: Stainless steel is widely used in the automotive industry in exhaust systems, fuel tanks, and other parts that require corrosion resistance. In addition to its corrosion resistance, stainless steel shows pleasing weld aesthetics.
• Magnesium: Magnesium is a lightweight material used in specific applications where weight reduction is critical. Typical examples are engine blocks, coolers, and transmission components.

Understanding the base material of the part is crucial in weld preparation. Each metal has different weldability; some, like aluminum, can be challenging to weld, so it is essential to understand what you are dealing with before weld repair.

Weldable Car Parts In Automotive Repair

Not all parts of the car are joined by fusion welding. The car industry also uses adhesive bonding and mechanical fasteners. The typical automotive applications for welding are:

• Auto-body panels: Auto-body panels, such as roofs, doors, fenders, hoods, and trunks, are made of thin sheet metal, which is often welded. However, it can easily be damaged. Severely damaged panels require a complete rework, and welding is a great solution.

• Chassis and Frame: The car's main structural framework is also welded. Welding applications include joining front and rear subframes, and it provides the required strength and rigidity.
• Exhaust System: Welders also join the thin-sheet components of the exhaust system, such as the exhaust pipes, muffler, and catalytic converter. Thus, you can quickly weld small leaks rather than replacing the entire system.
• Engine Components: Automotive welding repairs also include restoring some engine parts, like manifolds and engine mounts. In these applications, welding provides the required durability and performance.

• Suspension Components: Welders also repair and join suspension parts such as control arms, shock towers, and strut assemblies. Welding connects and secures various elements which can get damaged over time and require repair.

The pros of automotive welding repair are that you can restore most of the parts noted above, especially when the originals are too expensive. In addition, professional welders can build custom parts for car restoration, motorsport & racing, or offroad applications.

Welding Methods In Automotive Repair

The latest automotive industry uses some of the most advanced welding methods to deal with modern solutions and materials. However, for the home or autobody shop repairs, you are likely to use welding processes such as:

• MIG Welding
• TIG Welding
• Spot Welding
• Other welding methods (Stick or flux-cored arc welding)

Each shows different results depending on the parts you are about to weld. So, let's see the advantages and applications.

MIG Welding in Automotive Repair

MIG welding is one of the most straightforward welding methods, and many home, hobby, and DIY welders widely use it. At its core, Gas Metal Arc Welding (GMAW), or MIG (Metal Inert Gas) welding, uses an automatically fed solid wire. The weld is protected by shielding gas to avoid atmospheric contamination.

In automotive repair, MIG welding is the perfect choice for most beginners and new welders just getting into the trade. But that's not all. MIG welding is relatively fast, allowing you to get the job done quickly.

The versatility of MIG welding makes it perfect for automotive repair on material from 24-gauge up to 1/4-inch thick. Therefore, you can use MIG to weld both thin car panels as well as thicker car frames and structural elements.

Additionally, MIG welding is ideal for most common automotive metals, such as carbon steel, stainless steel, and aluminum. Its ease of use makes the process much more forgiving compared to other methods such as TIG or Stick.

TIG Welding in Automotive Repair

TIG (Tungsten Inert Gas) welding, or Gas Tungsten Arc Welding, is one of the most complex welding methods. However, the significant skill requirements also produce some of the highest-quality weld results.

Source: https://www.codinter.com/en/tig-welding-a-complete-guide/

Fundamentally, TIG welding uses a non-consumable tungsten electrode to produce a welding arc and melt and fuse the pieces. Depending on the thickness of the base metal and part fit-up, the process can be autogenous (fusion welding) or with added filler metal.

In automotive repair, TIG welding is ideal for thin, delicate, and heat-sensitive metals, such as aluminum, magnesium, or titanium. Common TIG repairs include welding exhaust systems, auto-body panels, magnesium blocks, etc.

The biggest advantage of GTAW in automotive repair is the excellent heat control it offers. Thin, non-ferrous metals such as aluminum or magnesium require the perfect amount of heat. Low heat can create a lack of fusion or incomplete penetration, while too much heat can cause burn-through or distortion. TIG eliminates these issues with pulse options or AC welding.

Spot Welding in Automotive Repair

Spot welding is a resistance welding method that uses heat from metal's electrical resistance and pressure to join the pieces. Unlike MIG or TIG, there is no electric arc, so the heat-affected zone is much smaller. Spot welding creates tiny, spot-like welds, which are perfect for thin sheet metal.

As a result, spot welding in automotive repair is perfect on auto-body panels. It creates tiny, nearly invisible spot welds across the joint, which is ideal for any panel joining and repair. However, this technique is not suitable for thicker parts and complex joint configurations. So, you can't use it for chassis, body frame, or suspension parts.

Other Welding Methods For Automotive Repair

For home automotive repairs, you are likely to use some of the arc welding techniques not above. However, in specific situations, you can use Stick welding or Flux-cored arc welding.

These techniques are known as flux welding methods. They use self-shielded electrodes and wires, which makes them perfect for outdoor repairs. However, there are reasons why they are not one of the primary methods for the job.

Shielded Metal Arc Welding (SMAW), or Stick/Arc welding, is the industry's favorite due to its low cost and high speed. The equipment is cheap and portable, which makes it perfect for minor automotive repairs. However, Stick doesn't work well with delicate and thin metals and produces more weld spatter. These cons make it unsuitable for delicate automotive parts and weld aesthetics.

Flux-cored arc welding (FCAW) combines the pros of MIG and Stick welding. Like MIG, FCAW uses an automatically fed wire, but unlike stick electrodes, the wire has a core filled with flux. FCAW is an easy and quick method for outdoor repairs, but like Stick, it doesn't work well with thin and delicate automotive parts.

Laser beam welding (LBW) is an advanced method used in the automotive industry. This method uses the heat of the laser to melt and fuse the pieces with great precision and highest quality. Laser welding is often automated and tailored for high-precision repetitive welds, but you are less likely to use its expensive equipment for home automotive repairs.

Tips For Automotive Welding Repairs

Automotive welding repair can be an exciting hobby or even a lucrative business. But, if you are new in this field, it will take you some time, practice, and patience to get everything right.

So, here are some tips and tricks for automotive welding repairs that you can find helpful for both beginner and seasoned welders. The entire process will significantly depend on the specific application, material type, or thickness, but in general, you will need to:

• Pay attention to welding safety
• Choose the appropriate equipment
• Prepare and clean pieces
• Control the heat
• Adjust the technique
• Practice, practice, practice

Welding Safety In Automotive Repairs

Safety is paramount in any welding application, including automotive repairs. Welding is a hazardous profession that poses various risks to hands, eyes, and skin.

So, before proceeding to the following steps, make sure your eyes and skin are well protected. Always wear a welding helmet, preferably an auto-darkening helmet rated for low amps, a welding jacket, and gloves. If you are repairing thin pieces, you can use thinner leather gloves for maximum dexterity.

Source: https://www.aws.org/

Choose the Appropriate Welding Equipment

Choosing the right equipment for your automotive repair applications is the crucial step. The choice will significantly vary depending on the type and thickness of the metal you are about to weld.

The welding market today is extensive, so you can find MIG welders, TIG welders, Stick welders, different wires, diameters, etc. But for an absolute beginner, we recommend an all-in-one, multi-process welder such as YesWelder Firstess MP200 . This versatile welder can weld and cut both thin and thick pieces of steel, stainless steel, and aluminum, which covers most automotive repair applications.

Regarding the consumables, you should match the diameter and type for the given applications. For example, thin metals at 20-22 ga require .023" wire or small TIG rods and tungsten. The filler composition should match the base metal. ER70S-6 is the most popular steel rod and wire, while aluminum requires ER 4043 or ER 5356.

Shielding gas choice depends on the type of metal used and the automotive repair welding process. MIG welding uses a C25 mixture of 75% argon and 25% CO2, but it is only suitable for steel. Pure argon is best suited for aluminum and non-ferrous metal or any TIG automotive repair applications.

Weld Preparation And Cleaning

Weld preparation is as essential as welding itself. So, before any automotive welding repair, make sure you clean and align the pieces. Clean pieces will yield high-quality results and less spatter or porosity, which is especially important in aesthetic applications.

Part fit-up and joint design are also important, specifically when working with thin sheet metal. Good design will provide better results and limit heat exposure, which is crucial in preventing distortion. Furthermore, you can add the chilling bar to speed up heat dissipation.

Control the Heat

When working with delicate and thin metals such as aluminum or magnesium, you must control the heat. Lower the amperage to reduce the risk of burn-through or distortion, which are the two most common defects in automotive repair of thin pieces such as auto-body panels or exhaust systems.

To further control the heat, you should use TIG welding and pulsed welding options. Pulsed welding oscillates between base amps and background amps, creating a perfect combination of heating and cooling. This feature reduces the overall heat exposure and heat-affected zone.

Source: https://bancrofteng.com/pulsed-welding-for-thick-materials/

In addition, you can also use the stitch welding technique to reduce the heat buildup. Stitch welding, or intermittent welding, involves using several short welds across the joint rather than one long weld. That way, you also reduce the heat and risk of distortion on thin automotive parts.

Pay Attention to Weld Technique

The welding technique includes adjusting the travel speed, travel angle, and working angle for the specific material and welding position. While this sounds simple, mastering these parameters can make or break the project.

The travel speed will depend on the joint configuration, welding position, and thickness of the metal. Going too fast can cause a lack of fusion, but it can be helpful in a vertical welding position when dealing with gravity. Going too slow will cause more prolonged heat exposure, resulting in burn-through or distortion.

The travel angle and working angle will depend on the automotive repair welding position. For example, a flat position is common with body panels, floor pans, and some frame repairs. Welders often join frame rails in a horizontal position in auto repair. Vertical welds are great for pillars or rocker panels, while overhead welding is suitable for any applications on the underside of the vehicle.

Practice is Crucial

Welding is a profession that requires a lot of time, practice, and patience, and automotive repairs are no exception. If you are new to this field, we recommend using scrap metal with properties similar to those of the parts you are about to weld. Practice will help you find the best results and sweet spot between parameters and techniques.

If you are an absolute beginner, we recommend first getting familiar with the welding process itself. YesWelder blogs are a perfect source of information for learning how to weld, how to set up and work with a machine, and different metals. Then, you can start getting familiar with the specifics of the automotive industry and the repairs themselves.

Final Thoughts

Welding is a crucial profession that drives the whole world together, including the vital parts of a car. Auto-body panels, frames, engine parts, and exhaust systems are just some examples of automotive welding applications, but each of these parts can break over time.

That's where automotive welding repair kicks in. Instead of buying new parts, you can repair most parts of these systems, or you can even build custom parts and improve your car.

However, like any welding application, automotive welding repairs require time, patience, practice, and an excellent understanding of welding operations. Nonetheless, mastering everything can make automotive welding repairs an exciting hobby or even a career.

1. What are the most common metals used in the automotive industry?

The most common metals used in the automotive industry are steel, advanced high-strength steel (AHSS), aluminum, stainless steel, and magnesium.

2. Which car parts can be repaired through welding?

Not all car parts are welded; some use adhesive bonding or mechanical fasteners. Common welding applications include:

• Auto-body panels: Doors, fenders, hoods, and trunks made of thin sheet metal.
• Chassis and frame: Structural framework for strength and rigidity.
• Exhaust system: Exhaust pipes, mufflers, and catalytic converters.
• Engine components: Manifolds and engine mounts.
• Suspension parts: Control arms and strut assemblies.

Welding restores damaged parts and is cost-effective, especially for expensive or custom pieces.

👏 You may be interested in the following:

• Welding Parameters Explained
• Pulsed MIG Welding Tips And Techniques
• How To Reduce Excessive MIG Welding Spatter