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WARNING
♦ If extra-high-strength steel is overstretched, it will sudden‐
ly extend to a length greater than that required!
♦ For reasons of safety, it is not permitted to heat up extra-
high-strength body steel when straightening it out (i.e. the
same rule that applies to standard body steel).
♦ It is permissible to weld ultra-high-strength steel in ac‐
cordance with the Workshop Manual using the specified
separating cuts and welding methods.
What are ultra-high-strength hot-formed steel panels?
As the name suggests, these are steel panels which have been
hot-formed (at temperatures between 900 °C and 950 °C). A spe‐
cial cooling process in the forming die gives the steel panels their
high-strength properties (hot stamping). Using ultra-high-strength
hot-formed steel panels makes it possible to reduce the vehicle
body weight without a loss of body strength. On vehicles with ul‐
tra-high-strength hot-formed steel, spot welding equipment with
inverter must be used (refer to catalogue for workshop equipment
and special tools).
Yield strength of sheet steel used:
Designation Yield strength
Standard sheet steel < 160 MPa (N/mm²)
High-strength sheet steel < 220 MPa (N/mm²)
Extra-high-strength sheet steel < 420 MPa (N/mm²)
Ultra-high-strength sheet steel < 1000 MPa (N/mm²)
Ultra-high-strength hot-formed
sheet steel
< 1000 MPa (N/mm²)
5.5.3 Special properties of aluminium
Aluminium is primarily used for the body structure of today’s ve‐
hicles with a view to reducing weight and increasing rigidity.
In vehicle manufacture, there are the following different types:
♦ Aluminium sheet panels
♦ Aluminium extrusions (must not be bent back into shape)
♦ Aluminium castings (must not be bent back into shape)
The properties of these components differ fundamentally from
each other. It is therefore essential to refer to the Workshop Man‐
ual for the relevant vehicle in the event of damage.
Note
♦
The instructions below only apply to conventional vehicles with
a steel body structure on which aluminium panels are fitted.
♦
For an overview of the areas in which these panels are used,
refer to the illustration in the relevant Body Repairs workshop
manual ⇒ Rep. gr. 00 .
General InformationBody Repairs, General Body Repairs - Edition 04.2018
5. Assessing damage 15
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