Adhesive and sealant

applications in the Body-in-

White segment
These days implementing lightweight materials is an overriding
consideration in vehicle construction, but car manufacturers still are
on the lookout for methods to improve stiffness, increase crash
durability and reduce metal/material fatigue, all the while
contributing to weight reduction.

Structural Bonding
Among all safety-related manufacturing applications in the
automotive industry, structural bonding is the most important.
Structural-bonding seams perform strength-relevant functions on the
body frame where structural adhesives complement spot welding and
reduce its use. Since the entrance of extremely high-strength epoxy-
based adhesives into the market, structural-bonding seams have
increasingly replaced spot welding. Because fixing is necessary until
the adhesive has cured, welding is still used.  

Structural-bonding is the ideal application field for the stitch bead

method. Because adhesive would normally be burned during through-
welding, its application is interrupted exactly at the locations where
through-welding takes place. The high application speeds required by
the process make a very fast application unit an absolute necessity.
Application units should also be designed to offer a long service life
and to deal with the near constant, high stress levels to which they
are exposed.

Hem Flange
Atlas Copco IAS has been very successful in applications for bonding
the outside and inside sheets in the hem flange areas of doors, hoods
and tailgates. Using our proprietary E-Swirl technology, it is possible
to improve the distribution of adhesive in the flange areas of
components. 

The main advantage is that the adhesive can enter the remaining
grooves more easily when the sheets are joined and ensure optimum
filling. If the cavities were not properly filled, air could be trapped in
small pockets during the subsequent sealing operation. This air, in
turn, could escape during the hardening process, thereby spoiling the
appearance and effectiveness of the sealing in resisting corrosion. If
too much adhesive is applied in these areas, cost intensive retouching
is required.

Anti-Flutter / Gap-Filler
The function of an anti-flutter application is to reduce or eliminate
any "fluttering" or vibration of the outer and inner panels relative to
each other. This application is more commonly used on horizontal
closure panels such as hoods and deck lids  ̶  and to a lesser degree
on vertical panels, like doors and lift gates.

The shape of the applied adhesive is also very different. Instead of a

bead, the adhesive is applied in the shape of a gumdrop or chocolate
drop. It is strategically spaced across the inside surface of the outer
panel, aligning with the shape of the inner panel.

The placement also provides support for the outer panel to pass
compression tests. It's developed to withstand loads, such as the
weight of someone sitting on the hood without causing a dent.

https://www.sunstar.com/rd/story/weld_bonding

http://www.autoremondilahendused.ee/en/tutorials_new/body-
repair/seam-sealing.html