Download Crash Repair of Adhesively Bonded Automotive Structures

Crash Repair of Adhesively Bonded Automotive Structures
GROUP SPONSORED
PROJECT OUTLINE
PR 20885
May 2013
Summary
The components in a modern car body are joined together by the OEM in
state of the art production lines using the best available technology and
expertise. Modern auto-bodies contain a range of different materials and
increasing quantities of structural adhesives. Weld/ rivet-bonded seams
offer greater structural stiffness, crash performance, corrosion resistance
and even process economics. But in many cases structures that are
adhesively bonded are constructed without taking into account how a
damaged component can be disassembled and repaired.
Crash repairs are not performed by the OEMs themselves, but by SME
repair garages, which do not possess the same level of equipment or
know-how as the vehicle manufacturer. Performing crash repairs on
modern automotive structures presents a serious challenge to the vehicle
repair industry. Specifically, dis-bonding an adhesive seam without causing
damage to surrounding panels is a major problem. Where SME repair
garages are not able to economically repair a vehicle, there is a direct
impact back onto the OEM vehicle producers. A method for performing
rapid, economical, high quality repairs on adhesively bonded structures
would benefit both the repair industry and OEMs alike.
Project objectives:
The objectives of the project are to develop a system using induction
heating that is accurately able to heat adhesive seams allowing disbonding of the adhesive without damage to surrounding adhesive or paint
layers. This will facilitate quick and economical repair of adhesively bonded
structures.
TWI Ltd, Granta Park, Great Abington, Cambridge CB21 6AL, UK. Tel: +44 (0)1223 899000
Crash Repair of Adhesively Bonded Automotive Structures
Project Concept
Industrial problem:
The automotive industry is using an increased volume of adhesively bonded structures in the production of
passenger cars. However, the post-crash repair of adhesively bonded joints is extremely challenging and
expensive because of a lack of technology to allow quick and accurate dis-bonding of joints.
Industrial need:
An affordable reliable method of dis-bonding adhesive joints is required by the crash repair industry. Without
such a method the economical repair of adhesively bonded automotive structures becomes increasingly difficult,
this in turn increases the proportion of vehicles scrapped. High scrappage rates mean a loss of income for
automotive repair SME’s and increased cost to insurance companies. This in turn pushes up insurance
premiums to private owners and increases the insurance group rating of the vehicles, which is detrimental to
the sales figures of car companies.
Technical concept:
Modern structural adhesives are extremely strong at room temperature, but soften at elevated temperatures.
The technical concept is to develop a tool using an induction heating method that is able to quickly heat up a
localised area of adhesive joint so that it is soft enough to be opened, allowing the removal of the damaged
panel. Traditional heating systems are not local in nature and can damage near-by adhesive seams and paint
work with their ‘waste heat’. The heat input in the concept system must be controlled so that other adhesive
joints and paint-work in close proximity do not suffer damage.
Objectives

To develop a method of targeted local heating that allows a specific adhesive seam to be dis-bonded.

To achieve a highly controlled heat input that does not cause damage to adhesive or paint work outside
the target heating location.

To design, build and validate a working prototype system able to accurately dis-bond adhesive seams in
a range of joint types and configurations in both steel and aluminium, for use in crash repair garages
Benefits

The system will allow small SME garages to perform economic repairs on adhesively bonded structures,
securing their future business

Vehicle scrap rate is reduced, resulting in lower insurance premiums for vehicle owners

Insurance companies favour repair over scrappage as this prevents expensive claims, cutting into
profits and consequently pushing premiums higher.

Reduction of vehicle scrap rate, reduces insurance group ratings, helping OEM’s to sell vehicles

Reduction in repair costs helps prevent the use of cheaper ‘non genuine parts’. By using OEM genuine
parts, the OEM generates a profit in repair and a higher quality repair is performed achieving better
vehicle safety.

Environmental benefits: A scrapped vehicle causes environmental damage as a result of its disposal, in
addition a new vehicle must be produced to replace it, with resulting energy consumption and pollution.
TWI Ltd, Granta Park, Great Abington, Cambridge CB21 6AL, UK. Tel: +44 (0)1223 899000
Crash Repair of Adhesively Bonded Automotive Structures
Approach
Project technical approach:

Development of a tailored induction heating system with control capabilities allowing varied penetration
depths to accurately heat a full range of joint types.

Develop a range of tool geometries to allow dis-bonding for all common automotive joint configurations
including; overlapping sheets, flanges and corners.

Optimisation of process settings required to heat varied panel thickness at varied depth. Set up simple
user guidelines for common applications of the system.

Validation of ability to selectively remove real panels in multi-panel configurations in a real repair
environment

Crash testing and assessment of repaired components

Production of design specifications to produce a working system
Work plan:
The project will be split into the following tasks:

Specifications for the system

Feasibility study of induction heating systems

Production of test specimens for dis-bonding trials

Induction system development

Dis-bonding trials on a range of materials and joint geometries

Industrial validation on real components, including crash testing

Health and safety aspects
Copyright © TWI Ltd 2013
Crash Repair of Adhesively Bonded Automotive Structures
Deliverables

A report detailing the developments, system specifications, functionality, user instructions for the
system and health and safety aspects.

Industrial trials will be performed on real repaired components. The repaired components will be
subjected to mechanical testing to validate the effectiveness of the system.

A working demonstrator system will be produced.
Price and Duration
The overall estimated price for the work is £150,000 (excluding VAT), which requires £25,000 over a project
duration of 18 months from each of 6 Sponsors. It is anticipated that the project will commence with an agreed
scope of work with a minimum of 4 Sponsors.
Further Information
For further information on how a Group Sponsored Project (GSP) runs please visit:
http://www.twi.co.uk/services/research-and-consultancy/group-sponsored-projects/
GSP Co-ordinator: Lizanne Capstick
Email: [email protected]
Project Leader: Sullivan Smith
Email: [email protected]
TWI Ltd, Granta Park, Great Abington, Cambridge CB21 6AL, UK. Tel: +44 (0)1223 899000