Precautions for
Aluminum Alloy Panel Repair
Aluminum alloy begins to corrode when it comes in contact with
different types of metal, especially steel, for an extended period of time.
This is called “galvanic corrosion.” It is important to clean off any iron
particles from the surface of tools or use tools designated for aluminum
only. Aluminum alloy develops an oxide film quickly to protect against
corrosion, but makes it difficult to achieve good adhesion for putty or
paint. It is necessary to sand and clean the surface and apply putty or
primer as soon as possible during repairs. Aluminum substrates do not
require application of epoxy primer before putty for corrosion prevention.
Work-hardening and cracking of aluminum panels can be prevented by
heating the alloy before working it. Heating the area will help to restore
contours to their original shape. Conduct heat related repairs no higher
than 392° F (200° C). When panel temperature rises above 572° F
(300° C), aluminum becomes very weak and may begin to melt. Follow
the instructions provided for using heat during panel repairs.
4 TOYOTA Repair Methods for Aluminum Alloy Panels