List at least four different types of welding joints used when making a sectional replacement. Discuss how each of them is made and where they are most likely to be used.

Question

What will be an ideal response?

Answer 1

Open butt joint- where two straight cut edges or surfaces must be fitted precisely
Offset butt joint – used where additional strength & joint integrity are required such as on a box design. The top side of the box would be welded either forward or to the rear of the bottom side of the box. Used where a sectional replacement is made on an A-pillar. Butt joint with insert- When performing a sectional replacement on a box section of a panel such as the rocker panel, an insert measuring in length between one half to two inches long and in the same shape as the box, is welded to the inside of it to ensure the joint area offers the same strength characteristics as the original structure.
Lap weld – involves lapping one layer of metal over the top of another and welding the surfaces together at the seam. Commonly used on passenger compartment floor, and trunk floor pans,
Tapered lap weld – Used making a sectional replacement on an enclosed rail. The edges of all four sides on the replacement section are cut to accommodate bending them inward so it can be slipped inside the original rail end and welded together at the edge of the seam.
Flanged / recessed lap - Commonly used when replacing exterior sheet metal parts where the replacement section is secured to the original panel. The edge of the original panel is recessed with a special recessing tool so when the replacement part is lapped over the existing section the surface will be flush to each other.