Toyota
Ford Kuga
 Service Manual
Body Repairs - General Information » Corrosion Prevention
Panel coatings and corrosion protection

Body steel panels are provided with a coating for corrosion protection purposes. The coating material is predominantly zinc in a variety of composition forms. Aluminum is also used to some extent.

Basically, all types of steel sheet can be coated.

A variety of coating processes are used:

  • Hot dip zinc coating.
  • Electrolytic zinc plating.
  • Organic coating.
  • Hot dip aluminum coating.

NOTE: Welding fumes are harmful to health. Make certain that the workspace is well ventilated and use welding fume extraction.

The following points must be noted when welding:

  • Zinc starts to melt at about 420C.
  • The zinc vaporizes at a temperature of about 900C.
  • The amount of heating determines the damage to the zinc coating, and therefore to the corrosion protection.
  • Resistance spot welding is particularly suitable for welding zinc-coated panels, because no widespread warming occurs.
  • With electrolytically zinc-plated panels there is no need for any special preparation because the zinc coating does not need to be removed.

NOTE: Coated panels have a higher electrical resistance, but this can be compensated for by increasing the welding current by 10 - 20% .

    More about «Corrosion Prevention»:

    Panel coatings and corrosion protection

    Corrosion protection measures during repair work

    Corrosion protection for the floor pan (example)

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