The automotive industry has advanced in ways that make cars faster, lighter, and safer than ever before. One of the methods to create better vehicles was to use Advanced High-Strength Steel (AHSS) and aluminum in the construction. These materials offer superior strength, durability, and weight reduction, contributing to improved fuel efficiency and safety. However, they also require specialized repair techniques when a vehicle is involved in a collision. Today, we are going to discuss the aspects of working with these materials during repairs, as well as the technologies required to ensure your vehicle is returned to its pre-accident condition.
Key Takeaways
- Advanced High-Strength Steel (AHSS) and aluminum are used in modern vehicles to improve safety, fuel efficiency, and durability, but they require specialized repair techniques.
- AHSS is stronger and lighter than traditional steel, while aluminum provides corrosion resistance and weight reduction, making both materials essential for modern vehicle construction.
- Repairing AHSS and aluminum presents challenges such as the need for precision welding, controlled heat exposure, specialized equipment, and different repair techniques compared to conventional steel.
What to Know About AHSS and Aluminum
For many years, cars were manufactured out of steel—a heavy yet durable material. Advanced High-Strength Steel (AHSS) is very much like traditional steel, but it is engineered to be lighter and stronger. The durability of AHSS enhances crash resistance. You can find AHSS throughout the structural components of vehicles, including the pillars, frames, and crumple zones.
Aluminum is another metal commonly found in modern day vehicles. The metal is significantly lighter than steel while still providing strength and corrosion resistance. Typically, aluminum is used in hoods, fenders, doors, and various structural components. The goal of its inclusion is to improve handling and fuel economy without depleting safety. Unlike steel, aluminum does not have the same elasticity, making it more difficult to repair without proper equipment and training.
Challenges of Repairing AHSS and Aluminum
Although AHSS and aluminum are commonly included in vehicle manufacturing, that does not mean they are easy to work with. AHSS and aluminum present challenges in collision repair that require specialized techniques, including:
Precision Welding and Bonding
AHSS has a higher tensile strength than conventional steel, meaning traditional welding methods can weaken its structure. Special welding and bonding techniques, such as resistance spot welding or structural adhesives, are required to maintain integrity. These processes ensure that the material retains its original strength and does not suffer from stress fractures or weak joints, which could compromise safety. Additionally, the welding process for AHSS often requires lower heat input and specialized electrode materials to prevent brittleness and maintain durability.
Heat Sensitivity
Aluminum and some AHSS grades are highly sensitive to heat. Excessive heat exposure during repairs can compromise their structural integrity, making controlled repair processes essential. For example, aluminum has a lower melting point and higher thermal expansion rate than steel, meaning improper heating can cause warping or weakening of the metal. AHSS, on the other hand, undergoes changes in its microstructure when exposed to high temperatures, which can reduce its strength and effectiveness in absorbing impact. This makes it critical for technicians to use temperature-controlled repair methods, such as induction heating or cold repair techniques, to maintain the integrity of these materials.
Specific Equipment
Unlike conventional steel, aluminum requires dedicated tools and workspaces to prevent contamination that can lead to corrosion or weakened repairs. Cross-contamination between aluminum and steel can cause galvanic corrosion, leading to structural deterioration over time. To prevent this, repair shops must have separate aluminum repair stations with isolated tools and work areas. AHSS also necessitates the use of advanced laser measuring and computerized frame straightening for precise alignment. These tools help identify even the slightest frame distortions and ensure the vehicle is restored to factory specifications with minimal margin for error.
Different Repair Techniques
While conventional steel can often be pulled and reshaped after a collision, aluminum tends to crack rather than bend, making traditional dent repair methods less effective. This means that rather than using traditional hammer-and-dolly techniques, specialized aluminum dent removal tools and processes, such as heat shrinking or panel replacement, are required. AHSS also has limited formability, meaning that replacement is often necessary instead of reshaping.
Once deformed, AHSS does not easily return to its original shape, making it difficult to repair without compromising safety. In many cases, specific structural components of AHSS vehicles must be replaced rather than repaired to maintain crashworthiness and longevity.
How Elmer’s Auto Body Handles Advanced Material Repairs
Some collision repair centers in South Jersey are better equipped for AHSS and aluminum repairs than others. At Elmer’s Auto Body, we are equipped to handle the challenges of repairing vehicles made with AHSS and aluminum. Our technicians receive ongoing training in the latest repair techniques and utilize state-of-the-art equipment to ensure accurate and safe repairs. We use:
- Laser measuring systems to assess and restore frame alignment with precision.
- Standardized welding and bonding techniques to maintain the integrity of high-strength materials.
- Dedicated aluminum repair stations to prevent cross-contamination and ensure high-quality results.
- Manufacturer-approved repair methods to ensure that all repairs meet factory specifications for safety and performance.
Looking for a Collision Repair Center in South Jersey for Structural Repairs?
The shift toward Advanced High-Strength Steel and aluminum in modern vehicles has changed the way auto body repairs are performed. For that reason, you need to choose an auto body repair center in South Jersey that has skilled technicians and the correct equipment. At Elmer’s Auto Body, we take pride in our state-of-the-art facilities and highly experienced team. We can handle even the most complex structural issues. If your vehicle has been in an accident, trust our team to provide high-quality, precision repairs. Contact us today to schedule an appointment at one of our convenient South Jersey locations.