Fundamentally, the weld itself can cause distortion of the substrate, due to heat. More commonly known as HAZ (Heat Affected Zones), the intense process of heating and subsequent cooling of the substrate can generate weaknesses in the metal and limit the structural integrity at the weld point. In certain applications the metal must undergo stress relief to ensure that the risk of subsequent changes to the metal is minimised.https://blog.belzona.com/embrace-the-cold-cold-bonding-vs-hot-work/
So this stuff has the same PSI as JB Weld ... yet
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So a unibody is just stitch welded - a spot weld every inch - on the seam - vid
So the local weld shop took another look for me and said JB Weld would trap moisture - so don't do it. The weld seam crack is at the gusset - for the transmission - so it should be ok for now. Just keep doing rust treatment - converter and inhibitor. Phosphoric acid, internal spray on the tube frame - and the cosmoline RP-342.
thanks - I went back this am and talked to the boss. So I'm just gonna do rust treatment - I just ordered a gallon of 85% concentration phosphoric acid. I also got Eastman internal frame spray. I got RP-342 in the mail - should be here soon. So - the boss is claiming that the resistance weld seam cracked due to internal rust and that it will keep spreading due to rust. He said that since it's to a gusset cross piece (to the transmission) then it should stop spreading and not be so bad. He said NOT to use any JB weld as that will trap moisture and make the rust worse. I asked him about drilling holes to stop the crack spreading - he said not in the seam. I said maybe high frequency arc weld - since it's hydroformed tube. He does TIG welding - so he knows what that is. No - he didn't think that would fix it. So the patch put in was hard to reach - so yeah - they hammered on it a lot. I think the seam crack was from all the hammering - since hydroform is lighter steel and can't handle torsion. But there is a rust hole right next to that seam crack - so I'm sure it's rust also.
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