Certain candidate methods of locally cleaning and pretreating aluminium forms (pressed sheet, extrusions, etc.) have been assessed against the requirements of adhesive bonding during the repair of automotive structures. This paper describes the stages in the preparation of repair bonds and details progress in the development of techniques to maximise bond strenght and durability. The durability of adhesive joints has been evaluated in Salt-spray/Breaking load experiments and selected specimens were subjected to Potentiodynamic Polarisation to evaluate their anti-corrosion properties. The most promising of the repair pretreatments is a flame-spraying technology known as "Pyrosil". This exploits the chemical conditions within an open flame to generate an amorphous silicate film in a rapid two-stage process. The anti-corrosion and adhesive bonding properties of these films will be reported with a discussion of their application davantages.
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