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% .

Panel coatings and corrosion protection

Corrosion protection measures during repair work

Corrosion protection for the floor pan (example)