Collision Repair Training | United States
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Current Events/News: Advantage Online: 2002 Archives
STUD WELDING TOOL FOR ALUMINUM September 9, 2002 -There’s more aluminum being used for body panels each model year. This is because of the advantages of aluminum, including higher strength with lower weight, natural corrosion resistance, and the ease of recycling aluminum. The increased use makes it more likely that collision repair facilities will have to work with aluminum body panels.Methods for straightening aluminum are similar to the methods used to straighten steel, but the proper tools and equipment must be used. Conventional stud welders, for example, cannot be used. Aluminum dissipates heat much faster than steel. Therefore the current output on stud welders must be much higher.
Pulling Out A Dent These are the steps to remove a small dent on an aluminum door panel using this tool. The first step is to protect sensitive electronic modules from the high current by disconnecting the battery. Plastic is used to prevent any damage to adjacent panels, and spark resistant paper is added to protect the glass from grinding and welding sparks. The panel is then cleaned with wax and grease remover.
Washers with threaded inserts are attached so that a pull can be performed (see Figure 5). Heat is applied so that the aluminum will reach the repair temperature making it easier to straighten (see Figure 6). The temperature must be closely monitored when heating, since aluminum doesn’t change color when heated. Heat monitoring strips or a noncontact thermometer are two methods that can be used to monitor the temperature of the surface. A steel rod and the equipment leverage bar are then attached to the washers to enable the damage to be restored to the original contour (see Figure 7). As outward pressure is used on the low areas, high spots are tapped down with a leather-faced slapper and a body hammer. The washers are then removed. If the dent is too low, more heat can be applied and a hand puller used to remove the remaining damage to the body feature line. The studs are removed by twisting them with a side cutting pliers. The washers and studs are removed from the panel and the remaining stud is ground away with an angle grinder. The repair area is sanded in preparation for epoxy primer and/or body filler applications. Conclusion Conventional steel stud welders cannot be used for damaged aluminum body panels. The high heat dissipation quality of aluminum requires a machine with a higher current capacity. The machine described in this article is an example of one type of equipment designed to perform this type of repair. |
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