We continue to see new materials being used every day to reduce vehicle weight and improve fuel economy. With the 2015 Ford F-150 being introduced with an aluminum body, the collision industry is now realizing that aluminum may be one of the materials that nearly every collision repair facility will begin to see more frequently over the next couple of years.
Beverage Containers
While we are not all familiar with aluminum vehicle repair, we have probably enjoyed a beverage or two that was packaged in an aluminum can. In reading some information from the Aluminum Association I learned that since they began tracking the weight of aluminum can in 1972 that the weight of the average can has been reduced by 38% through 2014. With innovative changes, the amount of material being used to package your favorite beverage has been reduced, while maintaining the strength and durability that is required for the application. So while you sip that beverage after work today, know that by reducing the weight of the can, that you can now enjoy more of it due to the manufacturer’s ability to gain greater shipping efficiency and package and transport it using less material!
Aluminum Light Vehicle Applications
Yes the F-150 is new. But if you look at the use of aluminum in light vehicles, the growth started many years ago. Information found on the Aluminum Associations web site shows that the amount of aluminum in North American light vehicles has grown each year for nearly 50 years! The average vehicle in 1975 contained less than 100 pounds while growing to nearly 400 pounds in 2015. That growth is expected to continue for at least the next 10 years with a projection of 547 pounds in 2025.
In 2015 nearly seven (7) billion pounds of aluminum will be used for vehicle production. While engines and other parts make up the majority of that usage, they are projecting that 11% of the total will be used on body and closure panels.
The projection is that by 2025, 26.6% of all body and closure panels for vehicles in North America will be made of aluminum. So the question is, what do you need for equipment if the growth continues at this rate?
Dedicated Aluminum Tools
Galvanic corrosion, which is caused by contact between two dis-similar metals (and exposed to moisture, water, salt, etc.) has been a concern in the collision industry for many years. To minimize or eliminate the risk of cross contamination, shops must have a dedicated set of hand tools that will only be used on aluminum panels. These hand tools include hammers, dollies, clamps, files, drill bits, saw blades, etc. Tools with serrated faces should never be used in aluminum repairs.
In addition to hand tools, power tools, parts carts, stands, workbenches and jacks are also a concern. Tools such as pneumatic sanders (and the abrasives used) will also become coated with particles from the material being repaired whether it is steel or aluminum. In simple terms, all tools needed to perform steel repairs must be duplicated and dedicated for aluminum repairs.
Not only is this an investment that the shop must make, but it is also requires a change in the shops culture. There can be no exceptions to the standard operating procedure (SOPs) and shop policies that require these dedicated tools to be used only on aluminum.
Aluminum Clean Rooms
One of the greatest challenges the typical collision repair facility will have is dedicating the space to performing aluminum repairs. To prevent cross-contamination, shops must install a clean room. The clean room can be a dedicated space separated by curtains or it can be designed similar to a spray booth with solid walls. Other options that the shop may consider adding to their clean room are a lift, welding fume extractor, storage cabinets, etc.
One of the key considerations for a clean room is size and placement in the shop. Not only is space a concern, but efficiency and cross-contamination should also be considered. Based on anticipated volume and types of repairs performed can impact the size of the room required to avoid bottlenecks. Shops may want to consider having their aluminum room in an area adjacent to the paint department. If the dedicated aluminum repair area is at the opposite end of the shop, the risk increases that a technician will be grinding, sanding or blowing off a steel panel while the aluminum repair is waiting to enter the paint department.
Aluminum Dent Repair Tools
With an increasing number of exterior aluminum panels being used, shops are sure to encounter panels that are either dented or creased. When working on steel panels, it has become common to use a stud gun to repair much of this damage. On aluminum panels, a dedicated aluminum repair tool is the required method. These tools use a capacitor discharge gun to attach the “stud”, “Hook, or “Rings” to the aluminum panel. Then using tools that provide support and leverage on the panel the technician can attach to one or more of these studs, hooks, or rings and use the tool to begin to aid in the removal of the dent or crease.
Dust Extractors
With the increased use of aluminum the collision industry is becoming aware of the potential risks associated with cross-contamination and airborne aluminum dust. Not only is there concern about cross-contamination between steel and aluminum panels creating potential paint adhesion problems or galvanic corrosion, aluminum dust also poses a combustion hazard. Through the repair process the airborne aluminum dust is particularly combustible, and can even be explosive. For example, a typical vacuum were to be exposed to a static electricity spark or a grinding spark, it could ignite and cause a fire or explosion.
To minimize or eliminate the risk of combustion, it is generally recommended that a dedicated aluminum wet mix air filtration system be used. In these system the aluminum dust is captured at the point it is created and then water is used to wet the dust to ensure that the potentially explosive aluminum dust particles do not become airborne within the unit or when the air is discharged from the unit.
Riveting Tools
Just like the aviation industry, as shops encounter parts that need to be replaced, it is common for the OEM procedure to require the use of rivets or other mechanical fasteners and bonding adhesives. There are several types of rivets that can be used during a repair. These include self-piercing, blind, solid, etc. In any one repair, it is most likely required that several types of rivets will be used. Rivet guns used for aluminum collision repair can be battery, hydraulic, pneumatic/hydraulic. Depending the gun they may be capable of rivet installation, removal or both. One factor to consider is the ability of the gun to provide consistent force during the installation.
Because of the multiple fasteners used, processes need to be developed to properly identify the types and quantity at the time parts are ordered, assist technician organization during the repair, and ensure proper invoicing to the vehicle.
Welders
Many of the OEM repair procedures require the use an aluminum MIG welder for panel installation. A common requirement for an aluminum repair certification is that the shop must have a 220V pulse MIG welder specifically designed for welding aluminum.
When welding aluminum, using a pulse welder provides the ability to use spray transfer while minimizing heat input onto the aluminum substrate. With this type of transfer. The pulsing occurs several hundred times per second, proving spray transfer at a much lower average welding current making it easier to weld thin aluminum.
Conclusion
As we look at any vehicle today, you would have to agree that the construction materials and design are changing. Regardless of the vehicle or the material used we need 4 things for a proper repair. Those are:
1. Knowledge
2. Proper tools, equipment and supplies
3. Skills
4. Access to OEM repair procedures
As shops plan their future, the strategic plans must include a strategy and budget for keeping current on the tools, equipment and supplies required to repair the numerous materials that will appear in the shop.
And don’t forget, you need to increase the number of 12 ounce curls you do to make up for the difference in having lighter cans!
About Spanesi Americas:
Spanesi Americas is a company created with the same passion and expertise Spanesi SpA has become known for globally since 1989. Spanesi Americas' mission is to bring new products and technologies to body shops in the Americas to enable technicians to perform repairs to a high standard of excellence.
Spanesi is your one-stop solution for collision repair equipment, including frame and structural repair benches, measuring systems, MIG and resistance welders, aluminum repair tools, and a complete line of spray booths, prep stations and aluminum repair bays. Our complete line of products are designed to make collision repair businesses and technicians as efficient as possible while repairing the most current vehicle technology.
For more details about Spanesi Americas products and solutions, call us at 1.224.SPANESI (772.6374) or by email at [email protected].
