Sheet metal, material information
Information about
- aluminum. See «Aluminum»(ref-431177-S34887802072011101900000)
- aluminum components. See «Aluminum components»(ref-431177-S23911709202011101900000)
- galvanized components. See «Galvanized components»(ref-431177-S09990583602011101900000)
- HSS / Boron steel. See «HSS steel»(ref-451808-S40734735042012020900000) .
Aluminum components
Aluminum components
Scheme 232
Galvanized components
Note. Those components which are available as galvanized replacement parts are displayed darker in the following illustrations. Those components not galvanized are displayed lighter.
Volvo uses a large number of body components of single-sided, double-sided and extra-thickness galvanized steel. This is to achieve the best possible protection against corrosion. Take care not to damage galvanized components when carrying out body repairs, or when grinding or sanding.
On completing work damaged galvanizing must be replaced with single component filler primer.
Scheme 233
Scheme 234
Scheme 235
Scheme 236
Aluminum
Aluminum
Certain components are manufactured of aluminum.
The aluminum plate is called ALMG3. It contains 3% magnesium to make it rigid enough for use in bodywork.
Aluminum sheet alloyed in this way is one of the non-hardenable alloys and so does not lose its strength when heated or welded.
Its melting point is 630 degrees C (1166°F).
It can be aligned and worked if you are careful.
Working on aluminum sheet requires training
Welding
TIG-welding is the most suitable method for welding aluminum.
MIG welding can be used for minor repairs - for example a spot weld that has come loose, small holes or a crack in the vicinity of edges.
Aligning
Try to push out the damage first.
Use a wooden mallet, rubber hammer or light sheet metal hammer.
Use a wooden or hard rubber counterhold.
Where large areas are involved, sheet may "harden" and be very difficult to align any further.
Such areas may have been subject to deformation hardening and therefore must be solution-annealed to restore their original characteristics.
Solution annealing
The deformation hardened area should be heated to 350 degrees C (662°F) with a cutting burner on low flame.
The temperature can be checked with a digital temperature gauge, thermostat or a piece of wood run over the sheet.
If the piece of wood leaves a faint brown mark, the temperature is approximately 350 °C (662°F).
Let the sheet cool and start straightening.
Solution annealing can be repeated until straightening work is complete.
Shrinking
Shrinking is done with gas flame or carbon rod.
The method is the same as for normal body panels.
Note. Aluminum will not change color or turn red when the temperature is correct.
The gas flame should therefore be applied to the sheet in the same way as for body panels but then be removed when the aluminum starts to rise: Cool quickly with a wet cloth.
Repeat until normal sheet tension is obtained.
Filing and grinding
If using a body file, be very careful, as aluminum sheet is very soft and the file can cut in very quickly.
It is preferable to use a grinding block with 60 grade paper.
When circle grinding use a low speed machine (1200 RPM) with grinding disc and 80 grade paper.
Base filling
Filling can be done with solder or plastic filler.
If filling with solder, use only ordinary body solder not solder paste.
Solder by rubbing the warmed flux onto the ground aluminum plate.
Use a soldering torch and normal steel wire brush.
Then continue solder filling normally.
Plastic filling can only be carried out when the plate is ground and clean.
Certain types of filler require the plate to be primed before filling.
Welding methods
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
| CAUTION | Always remove the battery cables before welding in accordance with: Battery, disconnecting . |
| CAUTION | Locate the welding ground connection as close as possible to the welding point. |
| CAUTION | If the welding must be carried out in the immediate vicinity of an electronic unit then this must be removed. |
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
Plug 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.
Scheme 237
Test weld several test pieces. Break the panels apart and measure the size of the welding lens diameter (A), see illustration.
Scheme 238
Note. Use welding primer on all internal flanges.
Add filling primer if there is grinding damage.
| CAUTION | Make sure that the spot welds take properly on both panels. |
Scheme 239
Grind down the plug weld.
| CAUTION | Only grind welds, not the adjacent panel. |