Volkswagen ID.4: Joining and separating techniques

Drilling

Drilling is used to detach resistance spot welds and rivets.

When drilling, make sure that no components located behind the relevant area are damaged. When detaching welded joints with two and more layers, the sheet metal remaining on the vehicle must not be weakened. Thoroughly remove swarf from cavities after drilling by vacuuming.

Protect magnetic components from swarf.

Saw-cutting

Thoroughly remove swarf from cavities after saw-cutting by vacuuming.

Protect magnetic components from swarf Short-stroke pneumatic saw:

• Fast cutting process.
• Sawing radii is possible.
• Can also be used for sharply bent profiles

Oscillating saw

• Precise, straight cuts.
• Low penetration depth, thus particularly suitable for doublelayer sheet metal panels.

Grinding

Grinding can be an alternative to drilling especially for detaching hight-strength welded joints. Spot welds, laser-welded joints or brazed seams can be detached through grinding. But make sure that the material located behind the relevant area is not weakened or damaged.

Protect magnetic components from swarf.

• Due to flying sparks, extensive measures for protecting vehicle and surrounding are required.
• Higher temperatures than during drilling processes, thus more damage to remaining material and corrosion protection.

Milling

For body repairs, a difference is made between ball-nose cutter -A- and BTR cutter -B-.

Ball-nose cutters are used, if BTR cutters cannot be used for detaching spot welds due to the spatial conditions.

When working with BTR cutter, be careful to keep the cutting edges straight in the high-strength steel. The hardened cutting edges can break very easily. Always work with a suitable tool (not a hand drill).

Protect magnetic components from swarf

Separating bonded joints

Bonded joints of the vehicle body can be detached by applying heat.

• Wear protective gloves and safety goggles.
• Avoid direct skin contact with adhesives.
• Avoid inhaling solvent vapours.
• Use adhesives only in well-ventilated rooms.
• Hazard warnings of the manufacturer must be observed.
• In addition, the applicable accident prevention regulations for each country must be adhered to.
• Observe the corresponding material safety data sheets of the adhesives.

Pulling out rivets which are only accessible from one side

• Remove paint and oxide layer from rivet head and clamping point for earth clamps.
• Fit earth clamps as close as possible to the rivets.
• Weld stud onto rivet.
• Use weld stud to pull out rivet.

• Resistance spot welding
• Solid rivet
• Pop rivet
• Incorrect riveting
• Overview of riveting attachments
• Making a flow-drill screw connection, pre-drilled hole in upper part

Overview of materials usedResistance spot welding