Aluminum components are going to have an increasing affect on the type of work collision repair shops see over the next several years, and training and certifications will be an important part of being able to accept jobs that involve more mixed materials. Cadillac has announced its own training program, the Cadillac Aluminum Repair Network, which is launching at the end of 2015 in anticipation of the release of the new Cadillac CT6.
The CT6 uses a mix of aluminum, traditional steel, and high-strength steel as part of its lightweight design. According to the company, the aluminum intensive structure (about 65 percent of the vehicle is aluminum) includes a mix of 11 different materials.
According to John Eck, collision manager for Cadillac's wholesale dealer channel, the bulk of the vehicle's body is aluminum, with traditional steel in the floor pan and high-strength steel in the A and B pillars. The vehicle also includes aluminum sheet on exterior components, aluminum extrusion along the rocker panels and front rail, and aluminum cast in the front wheel wells toward the cabin.
"In terms of joining techniques, in the manufacturing process we use self-piercing rivets and flow drill screws, along with aluminum resistance spot welding and laser welding," Eck says. "We also have 590 linear feet of adhesive in the car. The repair process won't use the self-piercing rivets, but structural blind rivets and flow form rivets instead."
The vehicle does include an aluminum ribbing in the castings, which Eck says created some minor challenges in terms of fastener locations. "But we have specific repair procedures to address that, and we'll have 3D imaging on all the procedures to help the repairer," Eck says. "However, Cadillac does not allow repairs on castings, so any damage done to those castings will require full part replacement."
There are 13 such castings in the vehicle that have not only reduced the vehicles weight by nearly 200 pounds, but also reduced the number of total parts and lowered the number of stress points. The vehicle uses 20 percent fewer parts than the previous platform design.
Dealership and independent body shops that want to be certified to repair the new vehicle will be audited annually through an extensive verification process to ensure they meet all requirements for training, tools, and facilities.
However, since many shops have already received training and certifications in aluminum repair through other entities, the Cadillac program will take that experience into consideration. "There's nothing unusual about the repair processes needed for the CT6," Eck says. "The replacement of factory resistant aluminum spot welds with structural rivets will add a level of complexity, but the procedures spell out the specific steps to address each weld. It's crucial you read and understand the repair procedures prior to working on the vehicle so you can handle the spot welds."
Program training will primarily be Web-based and managed through a partnership between General Motors and I-CAR. GM will offer CT6 collision repair information at no charge. Axalta Coating Systems will provide implementation and ongoing support for the program.
The required Web-based training will include a course on general knowledge of fastening techniques, and a second course specific to CT6 body fastening. There are also three required I-CAR courses: welding (WCA03), aluminum intensive vehicle repairs (ALI01), and aluminum exterior panel repair (APR01).
"We're also looking at other OEM certifications, so if you have aluminum welding certifications through Audi, Mercedes or Tesla, we'll look at that as acceptable," Eck says. "We know that Audi and Mercedes, for example, go through a very extensive welding training program. Our vehicle uses less welding, so that training is sufficient. We're trying to be market friendly and not put a burden on shops. I-CAR and other luxury brand courses that we've reviewed will adequately prepare them."
Shops will need to have that certification in order to purchase aluminum repair parts through Cadillac dealerships. "For structural parts we'll have restricted distribution," Eck says. "The shop can order as long as they have a VIN and an authorized repair network account number for each facility."
Information on the Cadillac Aluminum Repair Network will be available at the www.genuinegmparts.com site in the first quarter of 2016, including technical documents, service bulletins, paint information, warranty information, VIN, and other data.
