Page 49 - Australasian Paint & Panel Magazine Jan-Feb 21

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High Strength Steels, aluminium in various forms such as castings and extrusions, mag- nesium and carbon fibre are also being used more widely than we have ever seen before.
Structural straightening is generally not an option on multi material bodies, using a straightening system to realign a multi material body can cause catastrophic dam- age to the structure. This has seen OEMs who have recommended bracket type benches for years, now move to highly ac- curate 3D measuring systems instead.
You should never accept a vehicle with mixed materials in your shop unless you and your technicians have undertaken the necessary training and invested in the right equipment.
MULTI MATERIAL WORK BAYS
Multi material work bays are becoming part of many OEMs approved tooling re- quirements. Having a designated area that will allow repairers to work safely with the various materials on mod-
ern vehicles is something that should be a vitally important con- sideration for any business. There are significant safety issues that have to be taken into account when working with multi material vehicles. Having the cor- rect dust extraction system is key to a safe multi material work bay.
Using a standard vacuum type dust ex- traction system could potentially create an explosion due to the different materials combining under the right conditions. Alu- minium particulate matter and iron oxide (rust) plus a strong ignition source can trig- ger a thermite reaction. The ignition source required to ignite this volatile mixture is 450°C, grinding sparks are around 980°C. Using a standard vacuum type dust extrac- tion system without a spark arrester could easily create that ignition point. This metal fire burns at temperatures of up to 2,400°C and cannot be extinguished with water, it creates an incredibly dangerous situation.
Keeping the work area dry and using an approved sparkless dust extraction system
will prevent this from happening, but the hazards are very real.
Attachment methods on these type of vehicle bodies have also got to be con- sidered. We are now seeing different types of fasteners used by OEMs to at- tach the various materials. The use of adhesive is widespread in multi mate- rial vehicle bodies, this not only pro- vides an incredibly strong bond when applied correctly but can also prevent any type of cross contamination be- tween the components.
Flow drill screws, friction element welding, clinching and various types of rivets can be found across the vehicle structure. Understanding how they are applied and, more importantly from a repairer point of view, how they are re- placed during the repair process are vi- tally important to carry out a safe and proper repair.
Structural straightening
is generally not an option on multi material bodies.”
From repairability of the various compo- nents to safety concerns when working with multi material bodies, knowledge and understanding of the processes are becom- ing ever more crucial. The importance of training becomes key to understanding what is involved in any potential repair but, just as importantly, key to carrying out those repairs in a safe, controlled environ- ment where repairers, insurers and the ve- hicle owners can all be confident that the vehicle will be repaired to manufacturer standards, and that it will react as expected in any subsequent accident.
I-CAR offers an array of courses to equip you and your team to safely repair mixed material vehicles, including foundation courses to start you off. Visit: I-CAR.com.au