UltraLight Steel Auto Body - Final Report - American Iron & Steel ...

ULSAB Final Report
3.5.2 Adhesive bonding
Final assembly: the assembly package tray upper drops onto the
package tray lower; the assembly panel back attaches to the
back of the floor complete; the body side outer assembly is
brought onto the side of the body; the fender rails support outer
are attached; and, finally, the roof panel is dropped on.
After the body structure leaves the body shop, the assembly
radiator support upper is attached to the front end; the assembly
dash insert is attached to the dash panel; and the spare tire tub
(spare tire in place) is dropped into the rear trunk area.
Spare tire tub
Dash panel insert
Steel sandwich material cannot be welded, so the ULSAB parts
made of steel sandwich material employed adhesive bonding as
the joining technology. Adhesive bonding provides structure as
well as a seal. The bonding material is a two-component, nonconductive,
high modulus, high viscous, chemically curing
polyurethane adhesive / sealant that cures virtually independent
of temperature and moisture.
The parts to be joined must be held securely in place while the
adhesive bonding cures. The steel sandwich dash panel insert
was secured with adhesive bonding and then bolted in place.
27