Aluminum VS Steel Panel Auto Body Repair

Manufacturers in the automotive industry use both steel and aluminum for constructing the body of auto vehicles. Although steel and aluminum may look similar, they have very different qualities.

Strength and Weight

Two important qualities that differ in both metals are their strength and weight. Although steel is stronger than aluminum, the latter is lighter because it is only one-third of the weight of steel.

Due to the lighter weight of aluminum, it is becoming more popular in the automotive industry?because of the following:

• Increased dent resistance – manufacturers can make aluminum panels thicker while still reducing the total weight.
• Better fuel efficiency – lighter vehicles require less fuel; compared with steel body vehicles, aluminum body vehicles save up to 108 barrels of crude oil in energy.
• Improved braking – lighter vehicles brake more efficiently.
• Quicker acceleration – lighter vehicles move faster.
• Upper-level handling – lighter vehicles have more superior handling.
• Improved safety – aluminum absorbs twice the crash energy of steel.

How does the use of aluminum versus steel affect everyday work in your body shop?

Plenty. More and more car manufacturers are using aluminum in their cars, especially in luxury high-end models like Mercedes Benz, Land Rover, and Audi. Traditionally bodyshops have needed two different stud weld pulling systems for steel and aluminium. But, do you know what's different about the aluminum "stud welders" compared to the steel "stud welders"? Most dent-pulling systems for aluminum panels use a capacitor-discharge type of welding technology as opposed to a resistance-weld type stud attachment.

Why are they different? Simple, aluminum is an extremely good conductor of electricity. There isn't as much heat generated with aluminum as there is with steel when the current from a resistance welder is forced to go through the stud where it contacts the panel.

Resistance welding needs electrical resistance to make heat, which fuses the metal. It's possible to resistance weld aluminum, but it takes a lot more energy!

To overcome the physics, a capacitor discharge welder is used. These welders build up a great deal of electrical energy in capacitors that, when released, create a burst of energy that creates enough heat to fuse the aluminum stud to the panel.

To help create enough heat to fuse the stud to the panel without burning a hole in it, the aluminum studs have a small brad on the face of the stud that melts from the surge of energy that is released during the weld, and helps fuse the studs to the panel so they can be used for pulling the dent out of the panel.

Following dent removal, the studs are snipped off with side cutters, and ground flush with the panel, and the area is prepared for body filler.

It is more complex to repair aluminium panels than is to read. Aluminium is unlike steel in that it doesn’t have a “memory” or “desire” to return to its original shape once it’s damaged. It will want to remain in its damaged state, and you’ll need to apply different techniques to assist it in returning to its original state.

Aluminium also gets harder or stiffer when it’s damaged and again when it’s straightened. This is called “work hardening” and is a definite part of the understanding process.

Most of the time frustration occurs on the part of owners and techs alike. It’s like money walking out the door with nothing to stop it. Until now.

Glue Pull Tools Work on Aluminum or Steel

KECO?Body Repair Products?glue pull repair tools work on BOTH steel and aluminum, it does not matter. Because GPR is agnostic to the type of metal used in the components of a vehicle, it is possible to remove a dent from an aluminum panel or steel panel using the same tool. When working with steel or aluminum, the techs usually need to attach the studs to the body part by drilling into it, or by pulling the studs or keys out of the panel. The use of GPR techniques reduces the use of filler, saves more OEM paint, and improves the overall repair process by eliminating grinding, drilling, or welding. KECO glue pull tools essentially work on the same principle as normal drill/weld techniques: you manually pull out the dent, sculpt, fill, sand, prime, and paint. However, with glue pull repairs (GPR), you glue a removable attachment, called a tab, to the panel and pull the panel, without drilling or welding. Our attachments and adhesives are suitable for use with either steel or aluminum, so there's no need to have specialized tools or separate working areas.

Glue pulling is a straight swap for stud welding or wiggle wire setups where you utilize the pulling techniques and tools that they already have.

If you want to get into the aluminum body repair business tomorrow and become more profitable, we've got adapters, bars, or glue at a fraction of the cost of buying aluminum-specific tools and components.

Centipede GPR Tabs and U-Bolt Adaptor

With comparatively little investment, these two tools are capable of pulling a lot of glue. To make sure that you can do complete aluminum repairs, use them with the equipment in your possession.

KECO Centipede Crease tabs are highly versatile and do not cause more damage just by using them because they fix specifically what you need them to fix, no more or less. They allow the tech to work a large dent in small increments and to carefully pull stubborn creases without inflicting more damage (peaks and valleys). This is because the tabs are shaped and sized (widths, curved, straight) to fix the damage, nothing more or nothing less.

KECO offers a U-bolt adapter made of high-strength steel that slides onto a glued-on tab.

Techniques, Tools, and Training

KECO Body Repair Products?is in the business of making your job easier, whether you are a body shop owner, manager, or technician. Our GPR techniques allow for the use of available tools to repair aluminum components and panels without drilling or welding in order to produce a finished product that is equivalent to or better quality than that produced by traditional methods. KECO GPR tools for aluminum-body work require minimal investment, allowing you to repair parts you thought you could not and accept jobs you thought you had to turn down.

We?offer training conducted by our experienced, dedicated staff. For improved effectiveness, better repair, and more profits, your staff can learn how to use GPR techniques and instruments so that they are integrated into the shop's workflow. We offer one-, two-, or three-day, on-location training. Our skilled professionals love to share their experience and know-how so contact KECO today. Body shops are provided with training, no matter what their budget.

Contact?KECO today. We're going to help your store become aluminum proficient, so it can stay in business and retain customers.

Is Glue Pull Repair Possible for Aluminum Bodies?

As mentioned earlier, cars made with aluminum are generally lighter in weight when compared with steel. Another important difference between steel and aluminum is the fact that steel, when pressured, will naturally return to its original position. This is not the same for aluminum. Aluminum requires more pressure for each pull and it does not stay where it is pulled.

With that said, you may wonder if Glue Pull Repair (GPR) is possible on aluminum.

The answer to that is, “Yes.” GPR is not only possible but it is also the preferred method for specialized care on aluminum body vehicles.