Waking to the quiet revolution

For more than a decade there has been a quiet revolution in new vehicle design. Car construction has changed dramatically with the introduction of new materials and assembly methods, as well as bonding and welding techniques.
The downside for the collision repair industry is that the way these vehicles are treated during the repair process must also change dramatically. Repair methods of the past are no longer appropriate and can in fact be downright dangerous.
 
New materials
Most of the latest structural materials are new-age steels such as dual-phase, TRIP, boron, micro-alloy, press-hardened stainless, high and ultra high strength. On top of that there are now a lot of non-traditional bonding methods such as adhesives, rivets and laser welding. Initially they were used on high-end models, but for around the last 10 years high-strength steels (HSS) have been used on even ‘mum and dad’ type cars.
Each successive model release from virtually every brand contains higher and higher percentages of HSS to the point where some have more than half their structural body weight made from these materials.
 
A major issue in
collision repair?
It’s vital to restore a vehicle back to its original design strength. In the past, with traditional mild steel, that was straightforward. However HSS total changes the game. Some HSS, such as dual-phase steel, isn’t designed to be straightened – it must be replaced – and all HSS is extremely heat-sensitive. For example, a HSS spot weld that doesn’t use the right heat, intensity and tip pressure can result in a brittle join which will be a weak point in a future accident. That’s crucial, because modern vehicle safety technology such as airbags and seatbelt pre-tensioners need to deploy within milliseconds of an impact. If the vehicle structure is weakened through an incorrect repair, the safety systems won’t react as they should and occupants won’t get the protection they need.
 
Training
Training organisations are well aware of the need to up-skill the industry. I-CAR is doing its best to get the message out there, and there are now courses available to panel beating technicians where they can learn techniques for dealing with HSS. Bodyshop owners and technicians are beginning to get the message, too – I’ve sat in I-CAR group briefings and seen the shock on the faces of repairers when they realise that they’ve potentially been using the wrong methods to repair vehicles.
 
Identifying HSS
Although HSS is commonly found around the A-pillar, sills and B-pillar, it has no identifying marks and, once it’s painted, it all looks the same.
To make matters worse, two different grades of steel can often be laser-welded together so you can’t even see the join. Some vehicle manufacturers make information available but it’s pretty hit and miss.
As result, via PPG’s global links, we discovered a comprehensive source for repair methods, called Thatchamnet, and were able to introduce it in this region. It’s a website-based information portal from UK based organisation, Thatcham.
Through research in its own workshops, it not only identifies vehicle construction materials, including different grades of HSS, it also determines the most practical techniques to achieve efficient, safe and cost-effective repairs for a huge range of vehicles.
Step-by-step instructions, along with photos, diagrams and technical tips, are available for Thatchamnet subscribers to view or print off simply by logging onto the website. Rather than technicians having to guess what material they’re dealing with and the best process to use, they can print out detailed, easy to follow instructions on exactly how to correctly repair the vehicle so it will perform as designed in a future accident. PPG has deliberately kept the subscription cost to a minimum to encourage as many repairers as possible to take advantage.
Given that everyone involved – repairers, insurers and the owners – want vehicles to be repaired faster and safer, I hope this issue gets the attention it deserves. Many panel beaters get little or no formal training once they’ve completed their apprenticeship, so they need to realise that if they want to repair vehicles correctly they need to look for opportunities to upgrade their skills now.

To find out more about Thatchamnet, visit www.ppgaccess.com.au, click ‘Products’, then ‘Thatchamnet’, and follow the step-by-step process. Alternatively, ring the PPG Access helpdesk on 1800 627 798.