Peugeot 308: Repair : Components in aluminium

ESSENTIAL : Before any operation on the structure of a vehicle fitted with a traction battery, the vehicle must be disconnected electrical supply.

ESSENTIAL : Observe the safety and cleanliness recommendations .

ESSENTIAL : Observe the precautions to be taken for the pyrotechnic components .

ESSENTIAL : All personnel carrying out work on a vehicle fitted with traction batteries must have received specific electric vehicle training and be authorised to work on these vehicles(observe the regulations in force in the respective country).

ESSENTIAL : All personnel working on vehicles with a fuel cell stack must have completed the STELLANTIS training courses required to work on these vehicles(observe the regulations in force in the respective country).

1. General

1.1. Classification of aluminium alloys

Belonging to 8 families, aluminium alloys are many and various in their composition, properties and uses.

Classes from 1000 to 8000 : Each manufacturer uses a part reference alluding to class and composition.

1.2. Hardening method

There are the following hardening methods :

• Work-hardened alloys : Classes 1000, 3000, 5000 and 8000
• Alloys structurally hardened : Classes 2000, 4000, 6000 and 7000

1.3. Classes of aluminium used in car bodies

Example : Bonnet :

• The exterior panel is in type 6016 aluminium : CLASS 6000
• The inner panel is in type 5754 aluminium : CLASS 5000

2. Straightening aluminium panels

2.1. Reshaping

During reshaping operations, take all useful precautions to avoid stretching of the metal, as aluminium is more prone to this than steel.

Do not use dent removal tools which are hard or edged (steel hammer), but use soft materials (wood, plastic or aluminium).

In the case of aluminium, straightening should commence at the centre of the deformed area (as opposed to steel panels).

2.2. Smoothing out

In the smoothing out phase, manoeuvre the striker and dolly carefully to avoid stretching of the metal.

It is possible to shrink back limited areas of metal by local application of heat.

CAUTION : Maximum heat for maximum shrinkage of the metal : 150 °C.

ESSENTIAL : Use only an oxyacetylene flame.

ESSENTIAL : Use of a carbon electrode is prohibited.

Temperature check :

• In the absence of any existing visual guide marks, we advise use of thermal markers
• Marks made on the panel using a thermal marker in the heating zone change colour when the temperature is reached

2.3. Sanding and smoothing

Smoothing by the use of abrasive discs requires special precautions to be taken in the case of aluminium.

ESSENTIAL : Never use any abrasive that has been used on ferrous metals . Ferrous particles remaining on the surface of abrasives that have been used on steel, risk becoming encrusted in the aluminium.

Ferrous particles encrusted in aluminium can cause a weblike corrosion that spreads below the film of paint.

3. Aluminium welding using MIG

It is possible to weld aluminium using a MIG welding station that is specifically adapted for this metal type.

Some welding stations permit MIG welding of steel and aluminium as well as brazing, with the exchange of following equipment :

• Wire coil
• Torch, cable and supply sleeve assembly
• Welding wire rollers
• Gas bottle  (pure argon)

4. Applying mastic

ESSENTIAL : The application of polyester mastic directly on aluminium is strictly forbidden.

In all cases, before applying mastic, first apply a paint primer and leave it to dry.

Procedure before repairs : (AT6 / AM6 / AMN8 / ATN8 / eATN8) automatic gearboxRepair : Dent removal without painting