As you will be aware, a number of new vehicles are now being manufactured, using Boron and other High Strength Steel panels, which cannot be welded in the normal manner.  In particular, we understand that failure to abide by the correct procedures for fitting of panels may have the following effects: -

1. Invalidate the manufacturers warranty
2. Unsound welds which could affect the structural integrity of the vehicle
3. Contaminate the material of the undamaged mating panel, as well as the new panel being fitted.
4. Unacceptable levels of corrosion at the welded seam

In particular, these High Strength Steels will loose their strength if heated to the normal welding temperatures of around 1500 C.  For this reason a brazing technique is required in order to keep the applied heat at approximately 950 C.

It is apparent that adoption of an incorrect method of repair on these vehicles could have severe consequences not only upon the safety of the repair, but also in high levels of corrosion at a later date. 



Of further concern, is that the correct procedure for welding sections into structural areas of the vehicle i.e chassis legs, will often require the MIG braze to be left in its original condition rather than being ground back, as would be normal practice. 

Grinding back of these welds would, we understand, affect the structural integrity of the component and would have safety implications.  Evidently a vehicle which has a structural repair of this type will have identifiable weld joints in exposed areas which will show that the vehicle has been repaired.  It follows that the Claimant will not be indemnified since the vehicle has not been returned to its original condition.

There would, therefore, be good grounds to believe that there will be an increase in complaints as a result of these evident repair techniques.

In general terms therefore, the introduction of High Strength Steel into the structural elements of motorcars will result in: -

Higher Costs to the Repairer

1. Dedicated Work Areas
2. Investment in specialist equipment to undertake these repairs
3. Skilled welders trained in the use of MIG brazing techniques with a pulse welder
4. Increase in expensive consumables