SAAB WIS ONLINE

(03-07-801) MIG brazing, EU

TECHNICAL ADVICE - Quick information for your help
Bulletin Nbr: 03-07-801
Date: ........... Juli 2003
Market: All
MIG brazing, EU


Cars affected

Saab 9-3 (9440) CV M04-

Background

Some weld joints on the car have been replaced by a new type of weld joint using bronze rod, "MIG brazing". The areas affected are at the sill, the windscreen frame and the A-pillar. The distinctive feature of MIG brazing is that it is gold in colour.

For plate-metal damage where there is MIG brazing there is a new procedure and a new type of equipment is required. Before the Saab workshops have been trained and procured new equipment, damaged cars having MIG brazing must be taken to the nearest Opel workshop which has MIG brazing equipment. There is an "Opel Dealer MIG Brazing equipment" list in our IRIS database under Service Information - Technical News - Group 8 Body- MIG-Brazing. The list will be updated regularly and will appear under "What's New?" in IRIS. Should the occasion arise that an Opel authorised workshop does not have suitable equipment, contact one of the six approved suppliers for support. The list of "MIG- Brazing equipment suppliers" is in our IRIS database under Service Information - Technical News - Group 8 Body- MIG-Brazing.

Depending on equipment and plate-metal gauge, different types of settings are required for the welding machine, "welding parameters". This TN contains parameters for six pieces of approved equipment. Make sure that Opel authorised workshops and independent workshops engaged have parameters for the localised areas as well as the method concerned from WIS. In all cases pure argon gas must be used and the welding rod must be 1 mm.

Parameters for upper windscreen frame


Area
Type of joint
Plate-metal combination
Program
Method
Rod supply
Ampere
Manufacturer
1 Overlap 2.0/1.0 4 Pulse 2.6 Kemppi
1 Overlap 2.0/1.0 6 5 Cloos
1 Overlap 2.0/1.0 2 Short-arc 4 ElmaTech
1 Overlap 2.0/1.0 Pulse 60 (Trim -2) Migatronic
1 Overlap 2.0/1.0 4 Pulse 3.3 Fronius
1 Overlap 2.0/1.0 4 Pulse 4.3 Wieländer


Parameters for A-pillar/door opening


Area
Type of joint
Plate-metal combination
Program
Method
Rod supply
Ampere
Manufacturer
2 Plug weld 1.2/2.2 4 Pulse 2.6 Kemppi
2 Plug weld 1.2/2.2 6 5 Cloos
2 Plug weld 1.2/2.2 2 Short-arc 4 ElmaTech
2 Plug weld 1.2/2.2 Pulse 60 (Trim -2) Migatronic
2 Plug weld 1.2/2.2 4 Pulse 3.3 Fronius
2 Plug weld 1.2/2.2 4 Pulse 4.3 Wieländer


Parameters for the extension member, lower area


Area
Type of joint
Plate-metal combination
Program
Method
Rod supply
Ampere
Manufacturer
3 Overlap 1.1/1.2 5 Pulse 2.9 Kemppi
4 Overlap 1.1/2.2 4 Pulse 2.7 Kemppi
3 Overlap 1.1/1.2 5 5 97 Cloos
4 Overlap 1.1/2.2 6 5 89 Cloos
3 Overlap 1.1/1.2 4 Short-arc 5.2 ElmaTech
4 Overlap 1.1/2.2 2 Short-arc 4.0 ElmaTech
3 Overlap 1.1/1.2 Pulse 58 (Trim -1) Migatronic
4 Overlap 1.1/2.2 Short-arc 63 (Trim 0.3) Migatronic
3 Overlap 1.1/1.2 4 Pulse 3.3 Fronius
4 Overlap 1.1/2.2 2 Short-arc 2.3 Fronius
3 Overlap 1.1/1.2 4 Pulse 4.3 Wieländer
4 Overlap 1.1/2.2 4 Pulse 4.3 Wieländer


Parameters for inner A-pillar


Area
Type of joint
Plate-metal combination
Program
Method
Rod supply
Ampere
Manufacturer
5 Overlap 1.0/2.5 5 Pulse 3 Kemppi
5 Overlap 1.0/2.5 5 5 97 Cloos
5 Overlap 1.0/2.5 4 Short-arc 5.2 ElmaTech
5 Overlap 1.0/2.5 Pulse 58 (Trim -1) Migatronic
5 Overlap 1.0/2.5 4 Pulse 3.3 Fronius
5 Overlap 1.0/2.5 4 Pulse 4.3 Wieländer


Parameters for the extension member, upper area


Area
Type of joint
Plate-metal combination
Program
Method
Rod supply
Ampere
Manufacturer
6 Overlap 1.1 / 1.2 4 Pulse 2.7 Kemppi
7 Plug weld 1.1 / 2.2 4 Pulse 2.7 Kemppi
8 Plug weld 1.1 / 1.2 / 2.2 5 Pulse 3.0 Kemppi
9 Overlap 1.1 / 1.2 4 Pulse 2.7 Kemppi
6 Overlap 1.1 / 1.2 6 5 Cloos
7 Plug weld 1.1 / 2.2 6 5 Cloos
8 Plug weld 1.1 / 1.2 / 2.2 5 5 97 Cloos
9 Overlap 1.1 / 1.2 6 5 Cloos
6 Overlap 1.1 / 1.2 2 Short-arc 4 ElmaTech
7 Plug weld 1.1 / 2.2 2 Short-arc 4 ElmaTech
8 Plug weld 1.1 / 1.2 / 2.2 4 Short-arc 5.2 ElmaTech
9 Overlap 1.1 / 1.2 2 Short-arc 4 ElmaTech
6 Overlap 1.1 / 1.2 Short-arc 63 (Trim 0.3) Migatronic
7 Plug weld 1.1 / 2.2 Short-arc 63 (Trim 0.3) Migatronic
8 Plug weld 1.1 / 1.2 / 2.2 Pulse 58 (Trim -1) Migatronic
9 Overlap 1.1 / 1.2 Short-arc 63 (Trim 0.3) Migatronic
6 Overlap 1.1 / 1.2 2 Short-arc 2.3 Fronius
7 Plug weld 1.1 / 2.2 2 Short-arc 2.3 Fronius
8 Plug weld 1.1 / 1.2 / 2.2 4 Pulse 3.3 Fronius
9 Overlap 1.1 / 1.2 2 Short-arc 2.3 Fronius
6 Overlap 1.1 / 1.2 4 Pulse 4.3 Wieländer
7 Plug weld 1.1 / 2.2 4 Pulse 4.3 Wieländer
8 Plug weld 1.1 / 1.2 / 2.2 4 Pulse 4.3 Wieländer
9 Overlap 1.1 / 1.2 4 Pulse 4.3 Wieländer


Parameters for outer sill


Area
Type of joint
Plate-metal combination
Program
Method
Rod supply
Ampere
Manufacturer
10 Overlap 0.8 / 2.2 4 Pulse 2.7 Kemppi
11 Overlap 0.8 / 2.2 4 Pulse 2.7 Kemppi
10 Overlap 0.8 / 2.2 6 5.0 Cloos
11 Overlap 0.8 / 2.2 6 5.0 Cloos
10 Overlap 0.8 / 2.2 2 Short-arc 4.0 ElmaTech
11 Overlap 0.8 / 2.2 2 Short-arc 4.0 ElmaTech
10 Overlap 0.8 / 2.2 Short-arc 63 (Trim 0.3) Migatronic
11 Overlap 0.8 / 2.2 Short-arc 63 (Trim 0.3) Migatronic
10 Overlap 0.8 / 2.2 2 Short-arc 2.3 Fronius
11 Overlap 0.8 / 2.2 2 Short-arc 2.3 Fronius
10 Overlap 0.8 / 2.2 4 Pulse 4.3 Wieländer
11 Overlap 0.8 / 2.2 4 Pulse 4.3 Wieländer


Parameters for windscreen frame, lower section


Area
Type of joint
Plate-metal combination
Program
Method
Rod supply
Ampere
Manufacturer
12 Overlap 1.2 / 1.0 4 Pulse 2.7 Kemppi
13 Overlap 1.2 / 2.2 4 Pulse 2.7 Kemppi
12 Overlap 1.2 / 1.0 6 5.0 Cloos
13 Overlap 1.2 / 2.2 6 5.0 Cloos
12 Overlap 1.2 / 1.0 2 Short-arc 4.0 ElmaTech
13 Overlap 1.2 / 2.2 2 Short-arc 4.0 ElmaTech
12 Overlap 1.2 / 1.0 Short-arc 63 (Trim 0.3) Migatronic
13 Overlap 1.2 / 2.2 Short-arc 63 (Trim 0.3) Migatronic
12 Overlap 1.2 / 1.0 2 Short-arc 2.3 Fronius
13 Overlap 1.2 / 2.2 2 Short-arc 2.3 Fronius
12 Overlap 1.2 / 1.0 4 Pulse 4.3 Wieländer
13 Overlap 1.2 / 2.2 4 Pulse 4.3 Wieländer