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LORD Corporation Outlines Findings of Study with Ford on Weld Bonding Using Adhesives

Published on 2004-10-22. Author : SpecialChem

LORD Corporation, maker of Fusor® Automotive Repair Adhesives – the leading metal and composite bonding solution for automotive body repair – has announced results of a comprehensive study conducted with Ford on the use of weld bonding with adhesives.

According to John Hughes, Refinish Paint Technical Expert for the Ford Paint and Body Technology Center (PBTC), Ford now recommends weld bonding -- a process by which welding and seam sealing occur in one step. Hughes said weld bonding with adhesives results in better soundproof and leak-free attributes, as well as better corrosion protection without the need to use seam sealer as a buffer. For example, the 2005 Ford F-150 contains more than 186 linear feet of weld bonding and Ford is using the process extensively in most new products.

LORD worked with members of the PBTC in Ypsilanti, Mich. during the course of the last year to test and develop the standards. The result is practical knowledge and tips for successful application, as well as a new TSB to be released by Ford in late October that outlines Ford’s recommendations for weld bonding with adhesives.

The study validated that original factory weld bonded parts also should be weld bonded in the aftermarket using a Squeeze Type Resistance Spot Welder (STRSW) and adhesive. Any 2005 and prior Ford vehicles that were weld bonded would be replaced with STRSW and adhesive. In areas that the STRSW machine cannot reach, a MIG welder and adhesive should be used. Detailed information about this process will be outlined in the forthcoming TSB.

Ford has approved Motorcraft's TA-1, 50 ml and TA-1-B, 225 ml Metal Bonding Adhesive because it has been tested exclusively. Designed to create uniform bondline thickness despite differences in clamping techniques, the adhesive provides excellent corrosion protection, improved NVH while reducing cycle times, and offers a built-in color indicator since it turns from gray to green as adhesive cures.

Collaborative Trials Result in Application Knowledge

According to Bob Zweng, Senior Technical Service Representative for LORD Corporation, the testing performed by LORD and Ford on the new procedure resulted in a variety of findings that will help body shops establish best practices.

"Quality Class A resistance welding through adhesive is achieved best with proper welder settings," said Zweng. "This includes the correct tip pressure, amperage settings, gun/tip configuration and appropriate weld time."

Key suggestions resulting from the testing include the following:

  • Power Basics: Repair shops should be electrically equipped to handle resistance welders since inverter welders require a minimum of 60 amps, three-phase and 208-volt service. Voltage drop can cause welder performance problems and the recommended distance from power box to welder outlet plug should be minimal, less than 50 feet.
  • Welder Air Usage: Liquid cooled welders require minimal compressed air, improving duty cycle and decreasing the adhesive burnback. Air cooled welders, however, require large amounts of compressed air for cooling purposes, though some welders can be used in shops with single phase electrical units.
  • Manual vs. Computerized Welders: Although manual welders are typically cheaper, they may require additional training to master the machine and settings, as well as require longer set-up time. Computerized resistance welders, however, are typically simpler to operate as you simply enter your metal thickness and then proceed with welding.
  • Tip Shape: Although flat tips are most widely used, round tips also work well in welding through adhesive. High pressure is required to weld bond as low tip pressure causes excessive sparks and burn-through.

Technology in Action

LORD will demonstrate STRSW welding with adhesives at the National Autobody Congress and Exposition (NACE), to be held in Las Vegas Nov. 3-6. Ed Staquet, Technical Support Manger, and Nick Gervase, Northeast Zone Manager, will discuss Bonding Using Compression Spot Welding Adhesives on Nov. 5 from 8:30-10 a.m. and then demonstrate it in the action arena demo area at 1 p.m. on the show floor. During the action demo, Gervase and Staquet will bond a part on a car panel and then weld it with a compression resistance spot welder.

About LORD Corporation and Fusor Automotive Repair Adhesives

Developed by LORD Corporation, a pioneer and global leader in the development and manufacture of high-performance bonding solutions for more than 50 years, Fusor products are recognized to meet OEM standards and have been a proven solution in the aftermarket for more than a decade. In addition to a wide range of acrylic, epoxy and urethane products for metal and plastic bonding and repair, Fusor offers a line of sealers, foams, guns and other accessories.

LORD Corporation, with headquarters in Cary, NC and sales in excess of $440-MM, is a privately held company that formulates, produces and sells general purpose and specialty adhesives and coatings; designs, manufactures and markets devices and systems to manage mechanical motion and control noise and vibration; and develops products and systems utilizing magnetically responsive technologies. With plants in nine states and facilities in 12 countries, LORD Corporation employs more than 2,200 worldwide.

Source: LORD Corporation


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