Working with aluminum also requires special precautions related to worker safety and substrate preparation, as well as proper process mapping and site and workplace hygiene. This can result in a compromised repair – and a mark on the reputation of the repair facility. Sometimes, these panels may get riveted back together without the corrosion protection restored. However, the technician may remove this corrosion protection during panel removal or surface preparation, leaving bare metal exposed. Heavy duty truck OEMs can apply anti-corrosion coatings on aluminum and other metal panels where the rivets attach. If the joint is not properly sealed, an electrolyte such as an acid, moisture or road salt can quickly start the corrosion process. When it comes to dissimilar substrates, the laws of physics work against us: for example, when an aluminum panel comes into contact with a steel rivet, galvanic corrosion can easily occur. Rivets alone are great for holding panels together in the shop but with movement and vibration, fatigue and corrosion can result, leading to panel bond failures. There are several factors to consider when repairing with rivets. However, technicians in collision repair may lack the training and information for professional repairs that require rivet bonding. Most truck manufacturers use rivet bonding on side and back panels, front hood closures, headliners and many inter-structural reinforcements of the cab designs. Rivet bonding – the use of rivets combined with structural adhesives to join panels – is very common among heavy duty truck OEMs.
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