Metal Repair

Metal repair in the automotive industry - Henkel Adhesives - Learn more about metal repair.



Body rework and rebuild jobs are an important field of activity in body shops these days. There are many new tools and solutions to facilitate such work. This tutorial shows you the technique of chemical tinning and the different surface treatments available for surface protection.

Click on these links to see the advantages of

Surface conversion for corrosion protection

Tinning methods (soldering, chemical tinning)

Additional corrosion protection

Metal Repair: Additional Knowledge

Learn everything you need to know about the subject of Metal Repair.

Bare metal surfaces of car body shells are protected by a conversion layer in the form of a phosphate coating applied in the OEM paint shop and protected by an e-coat layer. A damaged coating can cause corrosion and must be rebuilt.  

During repair activities such as sanding, cutting or welding, the protection coating may be partially removed or destroyed. It needs to be rebuilt to reinstate the original level of protection.

So, how do you quickly and efficiently achieve a high level of protection by repairing damaged coatings?

Metal repair in the automotive industry - Traditional conversion coating.

Traditional method

  1. Prepared panel with bare steel areas and filler
  2. Blow off
  3. Clean with TEROSON VR 20 or Silicone Ex (as used by painters)
  4. Prime (spray can or spray gun)
  5. Drying time between 15 and 30 minutes
  6. Remove overspray
  7. Clean with TEROSON VR 20 or Silicone Ex again
  8. Clean application tools if spray gun has been used
  9. Continue with paint process
Metal repair in the automotive industry - BONDERITE wipe conversion coating.

BONDERITE wipe method

  1. Prepared panel with bare steel areas and filler
  2. Blow off
  3. Clean with TEROSON VR 20
  4. Wipe BONDERITE M-NT 1455 Wipes on bare metal surfaces
  5. Continue with paint process within the next few minutes (max. 15 min.)

Application: Benefits of the Bonderite wipe method

  • One-step wipe, no need for water rinsing (wash off)
  • Easy, clean and controlled application, for small areas, quick and eco-friendly
  • No need for mixing, stirring or spray gun cleaning
  • Easy disposal once the wipe is dry, no special disposal treatments
  • No overspray
  • No cleaning after applicaton
  • Can be applied in the spray booth
  • Very good on both edges and areas abraded down to bare steel / aluminium

Material facts & benefits of BONDERITE M-NT 1455 Wipes

  • Pre-saturated wipes that create a chromate-free conversion coating
  • Rust prevention performance twice that of existing systems
  • Improves adhesion of paint layers and sealers
  • Chromate-free
  • Low VOC
  • Replaces wash / etch primer
  • Effective alternative to zinc-recoating
  • H&S friendly

General note
BONDERITE M-NT 1455 Wipes produce a conversion which forms from a reaction with the above-mentioned metal surfaces to form real chemical bonds. The converted surface provides an excellent base for organic finishes, paints, sealers and most adhesives. This reaction greatly enhances adhesion and corrosion resistance of the subsequently applied paint (including primer where multiple coat systems are used), sealers and adhesives. The BONDERITE M-NT 1455 Wipes conversion coating process is a dry-in-place application and does not require subsequent cleaning.

Do's and Don'ts

Do apply on:

  • Aluminium
  • Zinc, zinc alloy
  • Rare bare steel
  • CRS (cold-rolled steel)
  • Galvanized steel
  • Stainless steel

Do not apply on:

  • Paint primers (1K or 2K)
  • Polyester body fillers
  • Residual paint coatings
  • Plastic parts

Do not dilute!

After conversion coating with BONDERITE M-NT 1455 Wipes do apply one of the below

  • E-coat
  • Base coat
  • Primer
  • Paint filler
  • Sealer
  • Adhesive

General note
Polyester Fillers are developed to have best adhesion on bare metal surfaces.

In case of impact and similar damage to metal parts, the surface needs to be repaired. Body shops today tend to use a tin solder paste.

Many actors of the automotive aftermarket are looking for a solution to replaces tin solder paste. The new technology combines easy processing properties with the performance of tin.

Metal repair in the automotive industry - Traditional repair with tin solder paste.

Traditional tin soldering

The traditional repair is done with tin solder paste and an open flame

  • Process is limited on steel surfaces
  • Solder paste contains lead (heavy metal)
  • Process is used with an open flame
Metal repair in the automotive industry - Chemical tinning, the 5010 TR method.

Chemical tinning – the "5010 TR method"

New technology: ready to use 2 component product

  • Process works on steel and aluminium surfaces
  • Excellent modeling properties
  • Contains no heavy metal
  • No open flame needed (safer working process, less dismantling work etc)

General note
The new development TEROSON EP 5010 TR combines easy processing properties with eco-friendly requirements.

Benefits of chemical tinning with TEROSON EP 5010 TR

  • 2-component cartridge with mixing nozzle (no manual mixing required)
  • Easy and precise application and an accurate mixing
  • Perfect to abrade
  • Excellent sag resistance
  • Best performance in modelling
  • “Cold” application (no open flame)
  • No disassembly of surrounding parts and components, e.g. side airbags, gas tank, interior, (no risks of open flame affecting electronics or other susceptible components)
  • No damage on e-coat, conservation waxes or paint

Material facts & benefits of TEROSON EP 5010 TR

  • Long open time (approx. 80 minutes)
  • Material curing can be shortened through the use of heating pads (FlexiTherm) or infrared heating (max. 60°C)
  • Low density (lighter than tin)
  • No shrinkage
  • Primer less on steel and aluminium
  • Unique led-free technology, compliant with OES and insure needs

Surface Conversion for Corrosion Protection

A repair with sanding, cutting or welding partially removes or destroyes the existing protective coating (phosphate coating applied in the OEM paint shop protected by an e-coat layer).
BONDERITE M-NT 1455-W is an innovative solution to renew conversion coatings in a safe and fast way.

BONDERITE M-NT 1455-W are ready to use wipes 

  • No additional equipment necessary
  • No etch primer is necessary
  • Chromate-free product

Click here to see an application example:

How to use BONDERITE M-NT 1455-W

Metal repair in the automotive industry - Surface conversion for corrosion protection.