Weird looking welds on Genuine Volvo muffler

johnnyfd · Post by **johnnyfd** » 01 Nov 2015, 20:28

The muffler was shipped to me like this a few days ago. It's for my 850 turbo . I have never seen welds that look like this and they appear to be squished or rolled as the metal was cooling. Has anyone seen welds like this before ? Opinions on their viability ? If they were pressed while the metal was cooling seems like this would make them more brittle and aerated ,possibly having small fissures within the weld . The customer service rep at FCP that I sent pictures to said that the welds don't look right. He also said that he contacted Volvo and they said this is the norm but he had another muffler coming in that he would compare it to. I don't want to have to return this muffler and put the job off longer but I will if I have to.

Post by **scot850** » 01 Nov 2015, 23:13

That weld does not look like it has formed correctly. Take it back/return it and ask for another. There should not be rust in the weld and in this case it looks like it is under the weld.

Neil.

johnnyfd · Post by **johnnyfd** » 02 Nov 2015, 14:22

According to a message I got from a customer rep . This one is also a genuine Volvo.

Post by **abscate** » 03 Nov 2015, 06:26

Overheated and it looks like a cold joint to me too.

And, of course, the failure mode will be three years from now.

Post by **regent** » 03 Nov 2015, 07:22

Just another 'Genuine' Item from FCP...
They seem to be getting better at this

If the Chinese Shade Tree Welder was a little drunk, this looks normal

Post by **JDS60R** » 03 Nov 2015, 14:30

Looks like automated mig. Possibly spray transfer
If it doesn't leak now I bet it will hold up for years. If it leaks now return it. These welds don't have to be as strong as many folks think. I do like the toes in the first pic better. Not the best weld but it should be fine for the application.

Here is one on a magnaflow. I see these all the time and they hold up without issue.

Post by **scot850** » 03 Nov 2015, 15:08

Those welds on the Magnaflow look like good welds, not those shown in the Volvo pictures. The Magnaflow show good penetration and smooth finish.

Neil.

johnnyfd · Post by **johnnyfd** » 04 Nov 2015, 01:28

An fcp rep told me today that fcp's genuine Volvo parts specialist spoke with someone at Volvo who said that the visible part of the welds is actually an additional layer which is laid over the regular weld bead to protect it from rust and this is the way they do these now. My first thought was that this is an excuse fabricated to explain away a really messed up weld from some crappy factory. when I thought about it some more the explanation made some sense to me.if this was the actual weld bead why would someone bother to go to the trouble of following the weld along as they went with a tool that pressed it down and rolled the weld ? why not just leave the bead as is in its good structural integrity ? why complicate the process unnecessarily and how would it even be possible without an extra set of hands to mold the bead before it hardened ? Maybe this is what jds60r was referring to as "automated mig" .the visible part does actually look like it was just laid on top and has not penetrated and mixed with the pipes metal.the magnaflow muffler in jds60r's photo looks similar but it is hard to tell because the picture is out of focus.jds60r : does it actually look the same I can't really tell from your picture and can you please explain how automated mig works and what you meant by spray?

johnnyfd · Post by **johnnyfd** » 04 Nov 2015, 01:53

regarding this issue.I found their reps' attitudes to be quite commendable . I am not accustomed to this level of helpfulness from an online parts vendor .

Post by **regent** » 04 Nov 2015, 11:51

johnnyfd wrote:..I found their reps' attitudes to be quite commendable...

...and that is the exact thing to be expected from any reputable business, inclusive of a prompt corrective action