Why you need to get on board with aluminum repair

Aug. 14, 2015
Like it or not, aluminum is now here for the masses and more OEMs will be utilizing it in the coming years.

Like it or not, aluminum is now here for the masses and more OEMs will be utilizing it in the coming years. 

Aluminum has been around in the automotive field since the early 1900s, but for most, the aluminum-intensive vehicles started about 20 years with the Audi A8, followed by the Acura NSX, and then other high-end OEMs started producing aluminum-intensive vehicles. Honda was the first OEM to introduce an aluminum monocoque in an economical vehicle, the 1999 Insight, which was also a hybrid.  As we all know, Ford has now redesigned the 2015 F-150 as a monocoque cab and separate bed assembly of all aluminum, except the intrusion beams (BORON-alloyed steel) and the radiator core support (Magnesium). This aluminum body is bolted to a HSS frame. This is the first Body Over Frame (BOF) aluminum-intensive vehicle and based on what's being said in the press, there will be more OEMs following this design in the future.

Now don't be mislead; aluminum-intensive vehicles or hybrid-construction vehicles (steel and aluminum) have been around for the past 10-12 years, but we saw them mostly in high-end European luxury models and European sports cars. Ford has now opened the door for other OEs to design aluminum-intensive vehicles to the masses.  By 2020 (four and half years from now) the prediction is that about eight new models should be introduced, and all of these will be coming from US OEMs.  Therefore, what does this mean for you?

Although the F-150 is one of the most popular and best selling pick ups on the road, not every shop will see a 2015 aluminum one in their shop for at least two to three years.  We have spoken to many shop owners in more county type/rural areas where pick ups are the main means of transportation and the numbers might surprise you. One shop owner in Montana who I did training with said that last year they repaired 135 Ford F-150s, a staggering number. But when we asked how many 2013 and 2014 F-150s he repaired in 2014, the number dropped to four — all others were 2012 and earlier models. He further stated that he had sent away 15 aluminum-intensive vehicles to another certified shop in the next state, due to the parts restrictions. After our conversation, he decided to pursue getting certified by some of the European OEMs for aluminum repairs. So even in an area where the F-150 is king, they did not see that many current model year F-150s to make the investment worth it. This may now change your thinking on the investment of equipment to repair aluminum, but don't let this discourage you.

About seven years ago, Ford and Chrysler (Dodge/Jeep) produced procedures that require weld-bonding for replacement of their outer panels and some inner structural components on their steel vehicles. Chrysler also requires that the sectioning joints are butt joint with a backing all bonded as opposed to Ford, which requires a MAG-welded joint. Since 2007, BMW has required that all replacement outer panels on their steel vehicles be affixed to the vehicle with rivet bonding, even though the panels were weld bonded at the factory and all sectioning areas are bonded with an insert (butt joint with backing). For Ford and Chrysler repair facilities, they had to purchase Squeeze Type Resistance Welders (STRSW) and attend training on how to use this technology. Since 2007, most OEMs have adopted the STRSW process as the preferred method to reattach their panels cosmetically and structurally. As far as BMW repair facilities, they had to purchase rivet and adhesive guns along with attending specific training classes.  Now with the introduction of the 2015 F-150, a large percentage of repair facilities will need to purchase aluminum repair equipment and attend training classes on aluminum to be prepared for the influx of aluminum components and intensive vehicles in the next three to four years.

Ford, like all the other aluminum-intensive vehicle OEs, requires rivet bonding, bolted bonding, rivets and aluminum MIG welding for replacement procedures. Ford, also like the other aluminum OE programs, requires a specific listing of tools and equipment and a clean room to perform all aluminum repairs in. The cost of investment can exceed $70,000. Shops who want to invest in aluminum vehicle repairs must learn from those who have been involved in aluminum repair for years. Repair facility owners must be able to see a return on investment (ROI). Owners need to educate themselves not only on the repair procedures, but also on what their cost of doing business is and how much their labor rate needs to be to turn a profit. An analysis of cost per hour to operate must be reviewed. Owners who are involved with aluminum certification and have educated themselves have not only seen a rise in their labor rates for aluminum, but for steel vehicles as well.

My advice is to start making the investment now. However, I suggest you decide first what kind of repair facility you want to run. Most of the European OEM Aluminum Repair Programs require similar tools and equipment. So a facility might purchase all of the equipment for, let’s say, the Audi aluminum program and most of the equipment may already be approved for Porsche and even Mercedes-Benz, lowering the overall cost of investment.

In the case of Ford, most of the equipment and tools approved by the European OEs is approved by Ford for the F-150 program, but most of the Ford equipment is not approved by the European OEs. Case in point, we recently received a call from one of our clients who purchased all of the equipment for the Ford F-150 program. About two months after purchasing the Ford equipment, they were approved for the Audi and Mercedes-Benz aluminum programs. That was great news for them with one caveat —when they received the tool catalogs for Audi and Benz, they quickly learned that most of the Ford-approved equipment they had purchased was not on the Audi and Benz programs. Unfortunately the shop had to sell most of its Ford equipment, due to the fact that most of the Audi and Benz equipment was approved for the Ford program and the shop didn't need unused equipment. My point is to think about what programs you want to be in before making an investment and to avoid issues with purchasing redundant equipment and owning equipment that may not be used.   

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