Body Frame - General Information: Other Volvo S80 II

RUSTPROOFING

Special tools T9814075 SPRAY GUN Tool number: T9814075 Tool description: SPRAY GUN Tool boards: T9814076 SPRAY GUN Tool number: T9814076 Tool description: SPRAY GUN Tool boards

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see 9814075 and a hose nozzle with 360 degree spray pattern (see illustration). Insert the hose in the cavity and spray while slowly pulling the hose out.

If repairs are made to the body, the areas marked in the illustrations are to rustproof extra thoroughly. Use: Cavity protection, 116 1682

This applies, for example, to weld seams and areas that have been worked with in other ways.

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Use: Stone-chip protection, 116 1299

Apply stone-chip protection to the areas of the vehicle marked in grey on the illustration. see 9814076 .

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Use: Underbody protection, 116 1298

Apply underbody protection to the areas of the vehicle marked in grey on the illustration. see 9814076 .

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HSS (High Strength Steel) is a general term for steel material within a specific strength range.

The vehicles are built of different steel material, partly to optimize the body (impact safety, rigidity, fuel economy, etc.) and partly to make it as repair-friendly as possible. The steel material is classified into four different groups based on tensile strength, which is the force required to plastically deform the material.

1. Mild steel (MS). Trade steel with highest tensile strength of 180 MPa.
2. High tensile strength steels (HS). Steel with a tensile strength between 180 - 280 MPa.
3. Very high tensile strength steels (VHS). Steel with a tensile strength between 280 - 380 MPa.
4. Extra high tensile strength steels (EHS). Steel with a tensile strength between 380 - 800 MPa.
5. Ultra High Strength steel (UHS). Steel with a tensile strength of more than 800 MPa.

Mild Steel. This category of steel is used where use of a stronger steel is not necessary.

High Strength Steel There are three main types of steel in this category

1. Phosphorus-alloyed steel obtains is increase in strength with the help of the alloy matter phosphorus.
2. HSLA steel (High Strength Low Alloy) is a low alloy steel in which the steel obtains its increase in strength with the help of the alloy matter Vanadium, Niobium or Titanium.
3. DP steel (Dual Phase) obtains its increase in strength through the thermal treatment that the steel undergoes during manufacture. Then a two-phase structure of ferrite (iron) and martensite (carbon) is formed. This steel loses its strength when exposed to temperatures above 300°C.

Extra High Strength Steel. This category contains both HSLA and DP steel, but the strength has been further increased with greater additions of alloy substances.

Ultra High Strength Steel. There are two main types of steel in this category

1. DP-steel. Here, strength has been further increased with an advanced manufacturing process and with higher additives of alloy substances.
2. BORON steel obtains its strength through the use of the basic element boron and contains relatively large amounts of carbon. The plate profiles are formed heated between the die cutter and die cushion, where the material is also hardened. Due to its extremely high strength, it is difficult to straighten with good results. Grinding or plasma cutting is recommended when replacing BORON steel components. BORON steel welds well. It is not possible to galvanized BORON steel during the production process. It is therefore very important to rustproof these components extra thoroughly.

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WELDING, GENERAL

Note. The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.

Volvo bodies are manufactured to the highest quality. All bodywork repairs must therefore take place following the same principles. Use light tools. Take care of the surface coating, electro dip (ED) and phosphating.

Always use welding primer between welded panel flanges.

PRIOR TO WELDING

RESISTANCE SPOT WELDING

Resistance spot welding must primarily be used if the capacity of the welding equipment is matched to panel thickness. When carrying out resistance spot welding, grind down to bare metal.

Clean the surfaces with Scotch-Brite or similar to minimize zinc and phosphating damage. Apply welding primer between the panels.

Note. Always test weld in accordance with the method below. Always set the weld according to panel quality

MAG WELDING

Punch replacement part for plug welding.

Select size of hole for plug welding according to the following panel thicknesses

8 mm for thicknesses less than 2.5 mm

10 mm or more for thicknesses above 2.5 mm.

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Test weld several test pieces. Break the panels apart and measure the size of the welding lens diameter (A), see illustration.

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Note. Use welding primer on all internal flanges.

Add filling primer if there is grinding damage.

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Grind down the plug weld.