SSP - Structural Steel Guide

Service Training
Self Study Program ******
Volkswagen Collision
Volkswagen Group of America, Inc.

Volkswagen Academy
Printed in U.S.A.
Printed 1/2012
Course Number ******
2011 Volkswagen Group of America, Inc.

All rights reserved. All information contained in this manual
is based on the latest information available at the time of
printing and is subject to the copyright and other intellectual
property rights of Volkswagen Group of America, Inc., its
affiliated companies and its licensors. All rights are reserved
to make changes at any time without notice. No part of this
document may be reproduced, stored in a retrieval system,
or transmitted in any form or by any means, electronic,
mechanical, photocopying, recording or otherwise, nor
may these materials be modified or reposted to other sites
without the prior expressed written permission of the
publisher.
All requests for permission to copy and redistribute
information should be referred to Volkswagen Group of
America, Inc.
Always check Technical Bulletins and the latest electronic
repair information for information that may supersede any
information included in this booklet.
Trademarks: All brand names and product names used in
this manual are trade names, service marks, trademarks,
or registered trademarks; and are the property of their
respective owners.
Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Steel Types and Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Knowledge Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Note
This Self-Study Program provides information

regarding the design and function of new
models.
This Self-Study Program is not a Repair Manual.
Important!
This information will not be updated.

For maintenance and repair procedures,
always refer to the latest electronic
service information.
iii
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Introduction
The use of steels in current vehicles is essential due to its availability, low cost and high strength. Steel has
one of the highest strengths of all metals, and allows for different levels of flexibility depending on how it is
processed.
It is possible to produce vehicles without steel. However, using other materials to achieve the same strengths
increases cost. Aluminum, magnesium, titanium and carbon fiber are all materials that can be used to make a
vehicle. Some of these materials are actually used in Volkswagen vehicles, but the primary material for the body
components is steel.
S421_080
This SSP will cover the steels used in Volkswagen vehicles, where they are used and general repair information.
There are variations in the types and colors of steels used in the graphics. Please refer to the legend for each
model . Do not assume that a particular color indicates the same strength steel for all vehicles.
Steel Types and Usage

Steels
S421_092
Special steels are created for use in different parts of the vehicle. These steels may have different hardnesses
and flexibility depending on the composition and treatment processes. The use of these different steels
increases the strength of the occupant cell and allows for high chassis stiffness, while reducing vehicle weight.
Basic Steel Types

Ferrite: Up to 28 MPa
Pearlite: 55 - 70 MPa
Austenite: 88 - 105 MPa
MPa is the abbreviation for MegaPascals.

MPA is a unit used to measure tensile
strength. Tensile strength increases as
the MPa number increases.
Cementite: Up to 215 MPa

Bainite: 15 - 220 MPa
Martensite: 170 - 250 MPa
Alloying
One way to increase the strength of steels is to alloy, or add other elements to the steel mixture while it is
molten. Elements commonly added to steel for alloying are:
Chrome
Manganese
Molybdenum
Nickel
Niobium
Phosphor
Silicon
Nitrogen
Titanium
For more information regarding steel construction and treating methods, refer to SSP
******, Volkswagen *****

Treatments
In order to further increase the strength of steels or alloys, there are many treatments. These treatments are
broken down into three main categories:
Treatment Type
Treatment
Mechanical treatments
Cold Forming
Hot Forming
Thermal treatments
Hardening
Annealing
Normalising
Tampering
Thermochemical treatments
Case Hardening
Carbonitriding
Nitrating

Classification
After all alloying and hardening processes are applied to steel, the steel must be classified according to its
characteristics.
Classification
according to strength
Ultimate
strength
in MPa
Conventional steels
Up to approx. 300
High-strength steels
300-480
350-730
340-480
Higher-strength steels
500-600
600-800
Ultra-high-strength steels
>800
Ultra-high-strength
thermoformed steels
>1,000
Need help creating

comparison to other
steels to identify what
types of repairs and
heat ranges can be
performed.
Chart below is what
most OEMs supply.

Applications
When designing a vehicle, the strength and characteristics of steel are used in the computer modeling process.
Specific steels and thicknesses of these steels are used in different areas to make the vehicle stiff and safe. In
addition, multiple sheets can be assembled with other steels to create parts with specific characteristics.
Tailored Blanks
Tailored blanks are different steel grades and
thicknesses to be joined together in a single part.
Tailored blanks allow for better and more precise
adjustment of the body structure to the loading of
certain body sections. This allows parts with complex
shapes and precisely fitting designs to be produced.
The individual parts of the tailored blanks are joined
together by welding. After welding the blank can
then be shaped.
S421_039
Front Floor
Front Longitudinal Member
Darkening in color indicates an increase in sheet thickness

Ultra High Strength Hot Formed Sheet Metal
This type of metal is formed using special treatments that may include boron.
Although some aftermarket companies provide products and state that this material can be worked with,
Volkswagen requires that these parts be replaced if damaged. Also, these parts should not be welded. They are
to be replaced according to the repair information.
These parts are usually used in the A-pillar, B-Pillar, some floor sections and the front and rear bumpers. ErWin
and ElsaWeb repair information both provide images of where these steels are located in General Information,
Hot Formed Body Panels.
Welding
Welding and Bonding Methods
There are many different types of methods used to hold the body together.
Spot Welding
Laser Welding
Laser Soldering
Plasma Soldering
Bonding
Each of the above techniques may be used depending on whether the parts are for crash safety, chassis
strength, deformation reduction, surface finish and many other reasons. In order to determine the correct repair
for any type of welding or bonding, always refer to the repair information.
Laser Welds
Bonding+Spot Welds
Welding
Laser Welding
Laser Nozzle
In laser welding, the heat to melt the materials

is produced by a laser beam. Laser welding was
first used to produce tailored blanks for body
construction. It is becoming more commonly used in
the assembly of vehicles due to:
Welding Rod Feed
Laser Beam
Welding Rod
Laser welding allows an almost seamless connection
of parts - this is particularly advantageous for connecting
higher-strength sheets
Complicated seams such as single-sided welds, are
possible
A very good surface quality is achieved even at high
working speeds
The surface of a laser weld seam is already so good
that reworking for a good paint finish only requires a
minimum amount of time
Sheet Metal
S421_059
Electrode
Spot Welding
This method allows electrically conductive materials
to be welded. An electrical current flowing through
the welding joint melts the material and the parts are
welded together - without additional material.
In modern body construction, adhesive is also
added to the joining level to improve the structural
behavior and stiffness of the joint and increase the
vibration resistance. The adhesive layer also prevents
penetration of substances such as water or other
liquids, preventing crevice corrosion.
Welding Spots
Sheet Metal
S421_067
Electrode
Welding
Soldering
Plasma Nozzle
Tungsten Electrode
In contrast to welding, the actual parts being joined

are not melted at the joint during the soldering
process. The solder material is bronze. The melted
solder fills the space at the joint and connects the
parts being joined with a high strength. Due to the
low temperatures used for soldering, the zinc coating
on galvanized sheet metal is less affected and
substantial hardening is avoided in the join area. Join
gaps can be bridged better by the solder. The lower
process temperatures allow less heat distortion.
Plasma Soldering
Solder (wire)
Inert Gas Nozzle
Wire Feed
Sheet Metal
Soldering Seam
Wire Nozzle
S421_123
Arc
Plasma Soldering
Laser Nozzle
Laser Beam
The arc is constricted by a plasma nozzle . This allows a

higher energy density and narrower seams. Also, higher
soldering speeds are possible.
Solder (wire)
Laser Soldering
Sheet Metal
Wire Feed
In LASER soldering, the soldering heat is produced by a

laser beam.
Soldering Seam
S421_072
Wire Nozzle
Laser Soldering
Bonding
Adhesive
Bonding is a method for the permanent connection

of components using an adhesive. Depending on
the type of adhesive, the hardening process can
be reinforced by heating the bond slightly. Due to
the continued development of new, more efficient
adhesives that are tailored to the applications,
adhesives and bonding processes are becoming
increasingly important in body construction. Bonded
joints can even be STRONGER than welding points.
Body Part
S421_043
Bonding
Repair
What Steels Cannot be Welded or
Repaired?
Volkswagen does not authorize welding or repair of
high-strength hot formed steels. These are the steels
normally found in the A- and B-Pillars as well as in
some floorboard components. They are clearly called
out in the repair information.
In this SSP, these steels are referred to as form
hardened.
These parts must be completely cut out in the areas
specified in the repair information.
Welding or repairing these parts may reduce the
crash safety of the occupant cell.
All other steels on the vehicle can be welded or

repaired, unless otherwise indicated in the repair
information.
10
Repair
Warnings and Cautions
The warnings and cautions listed below are only a partial list. Always follow the warnings and cautions in the
repair information, as well as common sense.
Both battery terminals must be disconnected and covered before any welding takes place
Be sure to locate the radio code before disconnecting the battery.
If any sparks from welding or grinding processes will get anywhere near the battery, the battery must be
removed form the vehicle. Batteries produce hydrogen gas, which is explosive.
Before reconnecting the battery, turn the ignition to the ON position. This assures that nobody is in the vehicle
with the airbag system is re-armed.
Airbag components must never be exposed to temperatures over 100C (212F) for even a brief period of time.
Airbag pyrotechnic components are or may be located (depending on vehicle model and options):
In the steering wheel
In the passenger front dash
In the sides of the front seats as side airbags
In the A, B and C-Pillar upper areas as a curtain airbag
In the rear side seats as side airbags
At the base of each outboard seat belt as a pyrotechnic seat belt tensioner
11
Models
2012 Beetle
The 2012 Beetle uses the latest in high strength
materials. Although the softer steels are still used
in many parts of the chassis, hot formed steels are
used in the front inner side panel, B-pillar and the rear
of the passenger compartment floor.
High strength steels are also used in the doors to
reduce side impact intrusion.
Welds:
Laser brazing used on roof area
Laser welding used in various areas throughout the body
12
Models
220 - 260 MPa

280 - 340 MPa
360 - 420 MPa
420 - 1000 MPa
> MPa (form hardened)
13
Models
2012 Beetle
The 2012 Beetle uses the latest in high strength
materials. Although the softer steels are still used
in many parts of the chassis, hot formed steels are
used in the front inner side panel, B-pillar and the rear
of the passenger compartment floor.
High strength steels are also used in the doors to
reduce side impact intrusion.
Welds:
14
Models
15
Models
A5 Golf
The A5 Golf and Jetta were the first to use the hot
formed steels. These were used in the areas of front
inner side panel and the B-pillar.
Welds:
16
Models
17
Models
A6 Golf
Hot formed high strength steels are used in the front
Welds:
18
Models
Up to 140 MPa
180 - 240 MPa
260 - 320 MPa
340 - 700 MPa
> 1000 MPa (form hardened)
19
Models
A6 Golf
Welds:
20
Models
21
Models
A5 Jetta
The A5 Golf and Jetta were the first to use the hot
formed steels. These were used in the areas of front
Welds:
22
Models
Hot Formed Steel
23
Models
A6 Jetta
inner side panel, B-pillar and parts of the floorpan.
Welds:
Laser welding used in various areas throughout the
body
24
Models
220 MPa
420 MPa
25
Models
A6 Jetta
Welds:
body
26
Models
27
Models
Jetta SportWagen
inner side panel and B-pillar.
Welds:
body
28
Models
29
Models
B6 Passat
Welds:
Laser Welds
Bonding+Spot Welds
30
Models
Up to 140 MPa
180 - 240 MPa
260 - 300 MPa
300 - 420 MPa
31
Models
B7 Passat
Welds:
32
Models
High strength steels are used in the door assemblies

to help prevent intrusion in a side impact.
220 MPa
420 MPa
33
Models
B7 Passat
Welds:
34
Models
35
Models
Passat Wagon
Welds:
36
Models
Up to 140 MPa
180 - 240 MPa
260 - 300 MPa
300 - 420 MPa
37
Models
CC
Welds:
body
38
Models
Up to 140 MPa
180 - 240 MPa
260 - 300 MPa
340 - 700 MPa
39
Models
CC
Welds:
body
40
Models
41
Models
Eos
inner side pane and parts of the floorpan.
Welds:
42
Models
Up to 140 MPa
180 - 240 MPa
260 - 300 MPa
300 - 420 MPa
43
Models
Eos
inner side pane and parts of the floorpan.
Welds:
44
Models
45
Models
2004 Touareg
Welds:
46
Models
47
Models
2011 Touareg
inner side panel, the roof crossmember and B-pillar.
For vehicles with a panoramic sunroof, the section
surrounding the sunroof is also hot formed high
strength steel.
Welds:
48
Models
Panoramic Sunroof
49
Models
2011 Touareg
inner side panel, the roof crossmember and B-pillar.
Welds:
50
Models
51
Models
Tiguan
Welds:
52
Models
Up to 140 MPa
180 - 240 MPa
260 - 300 MPa
340 - 700 MPa
53
Models
Tiguan
Welds:
54
Models
55
Special Tools
VAG 1731 Spot Weld Breaker
Pneumatic tool for removing spot welds during body
repairs. By exact positioning of the milling tool on the weld,
material weakening and damage to the paint is avoided,
which is unavoidable when grinding.
External spot-welds on edges, tapers and folds can be
removed in conjunction with the centering device, which
allows precise centering.
For the removal of internal, concealed and spot welds
with poor accessibility, the handgrip must be used. An
adjustment ring provides infinitely variable adjustment for
the milling depth. This prevents the back panel from being
drilled through and prevents contact with the centering
device.
Design and features:

Pneumatic spot-weld breaker with air-flow valve for
individual speed adjustment.
Recommended speed: approx. 1200 rpm.
Compressed air: 6 - 8 bar
Speed (without load): 2200 rpm
Weight: 1.8 kg
Items supplied:
Plastic case
Spot-weld breaker with centering device and high-grade
alloy milling cutter
8 mm dia. air-flow reduction valve
Hexagon key
5 replacement cutters
56
VAG 1731 Spot Weld Breaker
Special Tools
VAS 6322A Spot Weld Breaker
Pneumatic tool for removing spot welds during body
repairs. By exact positioning of the milling tool on the weld,
material weakening and damage to the paint is avoided,
which is unavoidable when grinding.
The spot weld miller VAS 6322A has a mechanically
supported pneumatic ejector. This enables ergonomic
working without exertion.
When the drill bit is deployed, the ejection speed can be
set individually by the user depending on the spot weld in
question. The use of relevant drill bits enables conventional
and higher tensile steels to be drilled.
A lower speed prevents the drill from overheating,
improves the cutting properties and increases service life.
VAS 6322A Spot Weld Breaker

Housing: Lightweight, polished aluminium
Drive: Pneumatic
Ejection: Pneumatic/mechanical
Bar: Hardened and painted steel
Replacement parts:
Technical data:
Compressed air: 6 bar
Drill bits (qty. 10)

VAS 6322A/2 or ASE 329 007 00 000
Motor speed: 1000

Connection: 1/4"
Contact pressure: approx. 240 kg
Drill bit (qty. 1)

VAS 6322A/3 or ASE 329 008 00 000
Noise level: 82 dba

Air consumption: 175 l/min, 6 CFM
Items supplied:
1 spot weld miller with small counterhold
Recommended accessories:
Counterhold, large VAS 6322A/1 or ASE 432 356 00 000
Manufacturer
2 drill bits for standard sheet metal VAS 6322A/2

1 drill bit for high tensile sheet metal VAS 6322A/3
Kamatec
1 tool case with deep inlay
57
Special Tools
VAG 2001B Welder
This fully digital aluminum shielded arc welding unit
VAG2001B has been designed specifically for repairs to
vehicles with aluminum bodies.
Operation is simple and convenient. Different welding
parameters can be set on a storage card system and called
up at the press of a button. Changes to the parameters or
updates to the equipment software can be carried out via a
new storage card system.
Good welding finishes can be achieved at lower heat
thanks to the quattro pulse function.
All the important equipment functions can be called up
without having to change the working position from the
handle.
VAG 2001B Migatronic Flex 300 Welder

Current Range: 15-300 A On duration 100%: 220 A/25.0 V
58
Special Tools
VAS 6388 Arc Welder
This fully digital aluminium shielde arc welding equipment
VAS 6388 has been designed specifically for repairs to
vehicles with aluminium bodies. Operation is simple and
convenient.
Technical data:
4 roller drive Burn-off pulse
Automatic cooler unit shutoff
Digital welding process control
Wire advance and speed
Wire feed without gas and current
Ground failure monitoring
VAS 6388 Aluminum Shielded Arc Welder
Automatic free burn

Gas test function
Job operation
Microprocessor control
Multi-process MIG/MAG, WIG and e-hand
Adjustable parameters:
Infinitely variable weld current adjustment via torch
Dynamics
Synergic operation
End crater current
Temperature controlled fan
Free burn time
Over-temperature protection
Gas advanced and run-on time
Modes of operation:
Hot start
Arc length and drop release correction
Welding output, infinitely variable
2 and 4 cycle operation with special 2 cycle

operation
Spot weld
Aluminium weld start (special 4 cycle operation)
Operating mode and process

Panel thickness
Dynamic, arc length and drop release correction
Current range: 3-270 A
Hold function, job number
Idling voltage: 50 V
Manual operation
Mains voltage: 3x400 V +/- 15% 50/60Hz
Motor current
Dimensions current source (mm):625 x 290 x 480
Weld speed, weld current / voltage (actual value, guide
Wire diameter: 0.8-2.0 mm
value)
Working voltage: 14.2-27.5 V
Service codes
Type of protection: IP23
Transition arc
Weight: 27.5 kg / 60.63 lbs
59
Special Tools
VAS 6530 Resistance Spot Welder
The VAS 6530 Resistance Spot Welder is recommended for
general body repairs on vehicles with high and ultra high
tensile strength steel panels, especially for workshops with
critical mains power supply.
The inverter technology in conjunction with adaptive smart
control makes quality spot weld joints possible. Variations
in joint structure are detected and compensated for if
possible. If a weld is not possible, a text warning message
will be issued by the unit.
Operation is by touch screen via three different welding
modes: manual, smart/automatic or manufacturer-specific
programs. With a USB interface, new welding programs
can be uploaded or recorded; welding results can be copied
for further processing on a PC.
The water-cooled C-transgun delivers equal electrode
contact force with electrode arms up to 635mm in length.
Specifications:
Mains connection: 230 V 3 Phase 60 Hz Breaker
protection: 60A delayed
Mains connection lead: 17 KVA Welding current max.:
14000 A DC Electrode contact force max.: 450 daN
(1011 lbs.)
Dimensions: 600mm (24")x 680mm(27.2") x
1220mm(48.8") Weight: 130 kg (286 lbs.)
Includes:
1 Main unit with inverter and touchscreen
1 Inverter C-transgun, pneumatic with short electrode
1 C-arm, length 85mm with electrode, water-cooled
1 Cart with rear large wheels and front braked castors
1 C-Transgun holder and swivel arm with adjustable
balancer
1 Water cooler module for transformer, transgun, arms
and electrodes
1 Rubber mains power cord, 8m retractable
1 Electrode cap key for electrodes up to DN 21
Resistance Spot Welder
60
VAS 6530/1 Accessory Package for VAS 6530 Includes:

1 C-arm, long, 505mm with angled electrodes, short
(water-cooled)
1 C-arm, small, air-cooled for wheel housings with ballhead electrode
1 Ball-head electrode, water-cooled with mushroom
head insert
1 Long angled electrode.
Water-cooled VAS6530/2 Accessory Package for VAS6530
Includes:
1 C-arm, medium, 355mm with angled electrodes, short
(water-cooled)
1 Support, long for offset electrodes
1 Offset electrode, water-cooled
1 Electrode, long straight, water-cooled on arm side.
Manufactured by:
TECNA S.p.A.
Special Tools
The resistance spot welder VAS 6535 features a central
connection and a tool detection function. An impedance
measurement is used to regulate the welding parameters
automatically. In this way, a constant level of quality of the
weld points is assured.
Weld processes can be stored and and to documented.
Disturbance variables such as dirt, adhesive etc. are
detected and compensated for. A compact flash memory
card allows the software of the unit to be updated at
any time. Mobile resistance spot welder with inverter
technology, can be updated, features impedance
measurement and welding parameter regulation.
Specifications:
Dimensions: 661mm (26") x 661mm (26") x 1372mm
(54") Weight: 171 kg (376 lbs.)
Includes:
Power Supply Unit Mains connection: 208 - 240V

3Phase
Mobile mains unit X tongs
Mains connection lead /length: 6mm2 / 10 m
Welding gun
Fuse protection at least: 60 A delay
Quick dent removal hammer
Mains frequency: 60 Hz
Linear balancer
Mains connection output: 42 kVA
Cooling Unit Heat Exchanger
Rated output at 50%
Special VAS Welding Programs
ED: 60 KVA
Idle voltage max.: 23 V DC
Options:
Welding current regulated: max. 12,000 A DC

Water tank volume: approx. 32 l
Ambient temperature: 40 C
Type of protection: IP21 X tongs
Cable length: 2.5 m
Welding current: max. 12,000 A DC
Weight of tongs without cables: 8 kg
VAS6535/1 Resistance Spot Welder Accessory Pack

Electrode set 02/06/415 MX coded
Electrode set 05 MX coded
Electrode set 11/280 MX coded
Abrasive sponge fine
Multi purpose electrode SB8 for planishing work
Electrode caps A 13 R 25 (6 pcs.)
Electrode caps A 13 R 15 (6 pcs.)
Manufactured by: Elektron, Bremen, Germany
61
Special Tools
Setting the welding parameters is carried out using simple,
self-explanatory symbols. The welding programs are for
high and higher tensile panels, for spot weld bonded
connections and for galvanized panels.
Individual storage of welding parameters is possible. In
addition, the system is suitable for documentation and
administration of work order details on A4 paper.
Software updates can be carried out using an SD card
(upload). The material recognition function is performed
with a material test program. Current control and pressure
monitoring is provided. The welding process is monitored
and the actual values are shown in the display.
The C-arms can be exchanged by means of a quick
positioning feature. The C-arms can be opened via a folding
catch, enabling access to the body behind profile sections.
Specifications:
Power supply 3 x 190-240 Volt 50-60 Hz.
Setting range 0-13 kA
Welding current: DC
Continuous duty 100 %ED 2,8 kA
Open circuit voltage 12 V DC
Max.Power with 5% ED: 156 KVA
Fuse (slow blow): 63 A
Connector cable (Cu): 5m / 4 x 0,157sqinch)
Includes:
Current source
1 CS transformer tongs
1 control unit with water tank 80 l
1 CS transformer tongs with integrated C-arm size 1
1 balancer with spring-loaded cable
1 mounting set for C-arms
Air pressure: 90 psi +/- 5%

Refrigerant: water + anti corrosive
Optional Accessory Packs :
Tank volume: 85 l / 22,5 gallons

Dimensions: 810x560x750 mm
Weight: 119 kg / 262 lbs.
VAS 6545-1 transformer x-gun with watercooling up to

the tips
3 x 200-240 Volt / 50-60Hz , 13.000 A / 65 A breaker.
VAS 6545-2 single sided gun for c-trafo aircooled, with
earth cable and accessory box
VAS 6545-3 single sided gun for x-trafo aircooled, with
ground cable and accessory box
Manufactured by: Wielander & Schill KG
62
Special Tools
VAS 6378
The dent removal tool VAS 6378 is an independent unit for
removing dents, pulling in sheet metal and tacking.
In addition, it also allows connection of an air puller as well
as welding on studs, pins, corrugated wire and U plates.
The tools included in the items supplied with VAS 6378/1
can be used as well with all other units of the system
thanks to the central connector.
The tool coding means the unit is given the correct
functional setting automatically.
Technical data:
Resistance welding unit WST 2000
Mains connection: Single phase 230 V (205 - 250 V)
VAS 6378 Dent Remover
Mains protection: Delay 16 A

Mains frequency 50/60 Hz
Mains connection output: 3.3 kVA
Welding output: 11 kVA
Idle voltage: 8 V AC
Welding current: Max. 3000 A
Ambient temperature: 40 C
Type of protection: IP 21
Dimensions H/W/D: 285 x 220 x 415 mm
Weight: 21 kg
Items supplied:
Dent remover
Main connection lead
Recommended accessories:
Accessory pack VAS 6378/1, ASE 435 167 00 000
Equipment trolley VAS 6378/2, ASE 435 168 00 000
Manufacturer Elektron, Bremen
63
Special Tools
VAS 6378/1 Accessory Package
Items supplied:
Welding gun 4 m with central connector
Panel beater's hammer
Puller tool
Contact piece U/B
100 discs B8 DIN 125
Carbon electrode diameter 10 mm
Ground clamp bar
Manufacturer: Elektron, Bremen
VAS 6378/1 Accessory Package
64
Knowledge Assessment
An on-line Knowledge Assessment (exam) is available for this Self-Study Program.
The Knowledge Assessment may or may not be required for Certification.
You can find this Knowledge Assessment at:
www.vwwebsource.com
For Assistance, please call:

Volkswagen Academy
Certification Program Headquarters
1-877-791-4838
(8:00 a.m. to 8:00 p.m. EST)
Or, E-mail:
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SSP - Structural Steel Guide

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SSP - Structural Steel Guide

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Service Training

Self Study Program ******

Volkswagen Group of America, Inc.

2011 Volkswagen Group of America, Inc.

Steel Types and Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

This Self-Study Program provides information

This information will not be updated.

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Steel Types and Usage

Basic Steel Types

MPa is the abbreviation for MegaPascals.

Cementite: Up to 215 MPa

Steel Types and Usage

Steel Types and Usage

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Steel Types and Usage

Front Longitudinal Member

Darkening in color indicates an increase in sheet thickness

Steel Types and Usage

In laser welding, the heat to melt the materials

Welding Rod Feed

In contrast to welding, the actual parts being joined

Inert Gas Nozzle

The arc is constricted by a plasma nozzle . This allows a

In LASER soldering, the soldering heat is produced by a

Bonding is a method for the permanent connection

All other steels on the vehicle can be welded or

220 - 260 MPa

Hot Formed Steel

High strength steels are used in the door assemblies

Design and features:

VAG 1731 Spot Weld Breaker

VAS 6322A Spot Weld Breaker

Design and features:

Drill bits (qty. 10)

Motor speed: 1000

Drill bit (qty. 1)

Noise level: 82 dba

2 drill bits for standard sheet metal VAS 6322A/2

1 tool case with deep inlay

VAG 2001B Migatronic Flex 300 Welder

VAS 6388 Aluminum Shielded Arc Welder

Automatic free burn

Infinitely variable weld current adjustment via torch

End crater current

Temperature controlled fan

Free burn time

Gas advanced and run-on time

Arc length and drop release correction

Welding output, infinitely variable

2 and 4 cycle operation with special 2 cycle

Aluminium weld start (special 4 cycle operation)

Design and features:

Operating mode and process

Current range: 3-270 A

Hold function, job number

Mains voltage: 3x400 V +/- 15% 50/60Hz

Dimensions current source (mm):625 x 290 x 480

Weld speed, weld current / voltage (actual value, guide

Wire diameter: 0.8-2.0 mm

Working voltage: 14.2-27.5 V

Type of protection: IP23

Weight: 27.5 kg / 60.63 lbs