32777 Welding Auto Body TG
Contents
1. AUTO BODY REPAIR WELDING TEACHER S GUIDE SHOPWARE INTRODUCTION This Teacher s Guide provides information to help you get the most out of Welding The con tents in this guide will enable you to prepare your students before using the program and pres ent follow up activities to reinforce the program s key learning points As part of the 12 part series Auto Body Repair Welding introduces basic welding concepts related to collision repair including different types of fusion welding the setup and functionality of the welding gun types of weld joints and how to make and test them and safety precau tions to practice when welding After viewing this video students will have a more detailed understanding of welding equipment and techniques used in collision repair and safety pre cautions to take when performing welding tasks Use the Welding video and accompanying activities provided in this guide to teach students basic welding techniques setting up the welding gun and metal assemblies prior to welding and welding safety practices LEARNING OBJECTIVES After viewing the program students will be able to BI Identify different types of welds E Explain MIG Welding techniques BI List considerations for planning a weld E Identify the correct tools to use given the task to be performed E Demonstrate a basic knowledge of welding operations and safety procedures lil Summarize proper preparations for welding EDU2. E Set up and adjust welding equipment for the material to be welded steel aluminum lI Determine proper welding technique push pull and gun angle for the type of welds being made BI Identify the type of weld joint butt lap etc for the repair being made lI Use the proper gun to joint angle and direction of gun travel for welds being made in all positions E Determine the correct type of weld continuous stitch skip plug spot etc and prepara tion for each specific welding operation E Identify the causes of welding defects burn through cracks in metal porosity improper pen etration excessive splatter distortion and waviness of bead make necessary adjustments E Insure proper work clamp ground location E Prepare the metal to be welded assure good metal fit up apply weld through primer if necessary lI Perform test welds Visually inspect and perform destructive test lI Protect vehicle systems and components including computers other electronic modules adjacent panel and glass from possible damage during welding and cutting operations E identify safety considerations Eye protection proper clothing respiratory protection shock hazards fumes material safety data sheet MSDS etc before beginning any weld ing operation 2004 Automobile Program Standards by the National Institute for Automotive Service Excellence ASE Copyright 2004 Reprinted with permission Language Arts and Communication
3. Metalshapers Association http www metalshapers org National Automotive Service Task Force www nastf org National Automotive Technicians Education Foundation www natef org Society of Collision Repair Specialists www scrs com Tektips Auto Body Pro Website www autobodypro com tektips htm BOOKS Duffy James E CAR Professional Automotive Collision Repair Albany NY Delmar Thomson Learning 2001 ISBN 0766813991 Duffy James E Auto Body Repair Technology 4th Edition Clifton Park NY Thomson Delmar Learning 2003 ISBN 0766862747 Killingsworth Jeff Eric Godfrey and John H Haynes The Haynes Suspension Steering And Driveline Manual Newbury Park CA Hayes North America 1998 ISBN 1563922932 32778 Dings Auto Body TG 10 1 04 10 55 AM Page 15 F OTHER PRODUCTS Automotive Technicians VHS DVD Cambridge Educational Sponsored by the National Automotive Technicians Education Foundation NATEF this pro gram explores automobile repair and collision repair NATEF works closely with Automotive Service Excellent ASE the nation s only industry wide certification program for automotive technicians Technicians with a sound education have a choice of career avenues Aside from fixing cars and trucks they can become service managers service engineers automotive writ ers or even auto technology teachers Order 24924 www cambridgeeducational com 1 800 468 4227 Automotive Technology Posters It only takes a
4. Divide the class into four groups and provide them with art supplies pencils magic markers scissors glue etc and poster board Instruct students to draw two columns one being twice as wide as the other and then to divide the columns into twelve rows The first row of the left column will be labeled Tool Supply and the first row of the right column will be labeled Function When To Use Instruct students to draw the tools supplies used for minor collision repair in the left column list provided below and insert a brief description in the right column of the function of the tool supply and when it should be used Tools Supplies Body Hammer Bumping Hammer Dent Puller Dinging Spoon Dolly Pick Pry Bar Shrinking Hammer Slide Hammer and Dent Puller Stud Spot Welder Weld on Pulling Tool Example Tool Supply Function When to Use Drawing of stud spot welder A welding gun that welds studs pins onto the surface of the dented metal panel Used with a slide hammer that attaches to the studs and pulls out the dent Used when there is no access to the back of the panel Friendly Feud The video presents valuable information about repairing minor damage to sheet metal includ ing tools and supplies preliminary tasks and repair and finishing procedures and techniques Divide the class into two teams have them choose a team name and provide each team with ten index cards Instruct the students to wri
5. PROGRAM DISCUSSION QUESTIONS 1 Now that you have seen the Dings and Scratches video why do you think an auto body repair professional should rough out a damaged area to within 1 8 of an inch of the original contour before applying any body filler 2 After inspecting a damaged quarter panel on a vehicle an auto body repair technician decides to repair the quarter panel rather than replace it What factors may have influenced the technician s decision 3 When straightening metal why should auto body repair technicians start with a light touch small taps light pressure and work up to harder blows and pressure if needed 4 What can happen if too much or too little hardener is added to the plastic filler and then applied to a damaged panel 5 Why might an auto body repair professional use a body pick or pry bar rather than a slide hammer and dent puller GROUP ACTIVITIES What s My Line In the video participants learn about different procedures and techniques to repair minor dings and scratches using specific tools and supplies Divide the class into groups of three Assign one tool or supply to each group e g body filler body hammer dent puller dinging spoon dolly glazing putty primer slide hammer and dent puller stud spot welder weld on pulling tool Instruct each group to research and document the characteristics of the assigned tool or supply Characteristics to consider include appearance purpose when the tool
6. Panic The Dings and Scratches video discussed certain procedures that must be performed prior to beginning the repair process Prepare a checklist of tasks auto body repair technicians should perform before actually beginning minor repairs After finalizing the list design a pamphlet to accommodate the checklist Consult the Dings and Scratches video the Internet fellow classmates and any other sources that you have available Categorize the tasks by similarities Some areas to consider include Damage Assessment Course of Action Planning and Safety Include checkboxes after each task and jazzy graphics or drawings Be prepared to share your brochure with the class 10 32778 Dings Auto Body TG 10 1 04 10 55 AM Page 11 F INTERNET ACTIVITIES Tech Tips Many auto body repair web sites include links to Web pages that offer tips and tricks on vari ous subjects Visit Web sites that contain tips about dent removal and scratch repair you may want to start at www metalshapers org Jot down five good tips that fellow classmates may find interesting or helpful Students will then share their tips with the class and vote on the most interesting or helpful tip presented Discussion Forums Visit www autobodyonline com and enter the discussion forums by clicking the Discussion tab in the upper left corner of the Web page Post a question about minor collision repair Ask about techniques that experienced auto body professionals have succe
7. Standards According to ASE NATEF standards the automobile technician must be proficient in the follow ing Language Arts and Communications related academic skills that are embedded in the occu pation The activities and information presented in this program and accompanying teacher s guide are aligned to the following standards from the National Automotive Technicians Education Foundation from the National Institute for Automotive Service Excellence E Request collect comprehend evaluate and apply oral and written information gathered from customers associates and supervisors regarding problem symptoms and potential solutions to problems E Identify the purpose for all written and oral communication and then choose the most effective strategies for listening reading speaking and writing to facilitate the communi cation process lI Adapt a reading strategy for all written materials e g customer s notes service manuals shop manuals technical bulletins etc relevant to problem identification diagnosis solu tion and repair lI Use study habits and techniques i e previewing scanning skimming taking notes etc when reviewing publications shop manuals references databases operator s manuals and text resources for problem solving diagnosis and repair 3 E Write clear concise complete and grammatically accurate sentences and paragraphs lI Write warranty reports and work orders to include information regarding p
8. any metal working trade Metal Shop Safety is one of a four part series that explains the need for safety procedures as well as precautions that can be taken to ensure a safe working environment The series also includes Auto Shop Safety Electrical Safety and Shop Safety Order 25897 http www meridianeducation com 1 800 727 5507 Multimedia Welding Safety CD ROM Shopware This multimedia CD ROM examines not only the welding process itself but also safety prac tices Through a combination of schematic diagrams video and animation sequences and still photos of tanks regulators and gauges welding makes sense even to the novice The user is led to explore topics including welding torches resistance spot welding arc welding and wire feed welding Navigation through the program is user friendly with options that allow users to review or bypass lesson segments A teacher s utilities section is also includ ed allowing teachers to monitor student performance and completion of lesson materials Multimedia Welding Safety is one of a four part series that explains safety procedures and precautions in a working environment The series also includes Multimedia Electrical Safety Multimedia Auto Shop Safety and Multimedia Woodshop Safety Order 20461 http www cambridgeeducational com 1 800 468 4227 17 Safety First Welding Shop Safety VHS DVD Cambridge Educational This program examines specific protective gear for welders in det
9. assess sheet metal damage plan for and perform minor sheet metal repairs using various tools and supplies and refinish surfaces A slide hammer dent puller weld on pulling tool body hammer and dolly and other tools of the trade are demonstrated After viewing this program viewers will be better prepared to properly assess plan for and repair minor collision damage using the appropriate tools and techniques MAIN TOPICS Topic 1 Introduction to Sheet Metal Tools and Supplies This section introduces the hand tools power tools and supplies that are used to repair minor dents without drilling holes in the sheet metal Students will view a brief demonstration of an auto body repair professional using a slide hammer and dent puller with a spot welder 32778 Dings Auto Body TG 10 1 04 10 55 AM Page 5 F Topic 2 Preliminary Tasks This section of the program describes procedures for examining and assessing the extent of damage determining whether repair or replacement makes the most sense the importance of devising a repair plan and safety precautions to take prior to beginning the repair process Topic 3 Repairing Damaged Sheet Metal This section demonstrates the procedures for repairing damaged sheet metal using power tools hand tools a stud welder and auto body supplies Students will learn the tools and supplies most applicable for each type of repair and the step by step procedures to repair damaged pan els that present varyi
10. creativity lI Use technology to locate evaluate and collect information from a variety of sources The National Education Technology Standards reprinted with permission from the International Society for Technology Education PROGRAM OVERVIEW The ability and knowledge to weld properly is one of the most useful skills an auto body tech nician can master A top quality weld is the foundation of professional collision repair This video Welding offers a behind the scenes look at the welding process in a collision repair facility Viewers will closely examine the functionality of the various parts of the MIG welding gun the most commonly used welding gun for auto body repair today and the method to set up the equipment prior to use The different types of collision repair welding techniques and weld joints will be explored including when to use them potential problems and quality test ing Viewers will also learn important safety precautions to practice in order to protect their body and surrounding property when performing welding tasks MAIN TOPICS Topic 1 Types of Fusion Welding This section of the program introduces the concept of welding and the different types of fusion welding including their suitability for collision repair Topic 2 MIG Welder Setup and Functionality This section of the program describes how to set up a MIG metal inert gas welder the type of welder most often used in auto body repair and how it wor
11. current in a circuit In collision repair reverse polarity or direct current DC reverse is typically used because it provides the best fusion due to a more stable arc pulling the weld A welding technique where the tip of the weld gun is angled toward the weld puddle as the gun is moved along the seam being welded Pulling the weld requires a slower travel speed than pushing pushing the weld A welding technique where the tip of the weld gun is angled away from the weld puddle as the gun is moved along the seam being welded Pushing the weld requires a faster travel speed than pulling and is more prone to burn through reinforced butt weld A variation of a butt weld that is formed by inserting another piece of metal same as that being welded behind the joint and running a continuous weld joint down the face of the joint fusing the insert to the other panels resistance spot welding pressure welding A welding process that heats metal by an electric current passing through the arms of the welder until the metal is softened and then fuses the metal pieces together using the two metal arms to apply pressure to both sides of the metal panels being welded Typical characteristics are small round weld beads Most often used during the vehicle manufacturing process less commonly used in collision repair due to restricted access to both sides of the panels being welded shallow penetration A condition that occurs when the MIG welding gun i
12. maintain their structural strength RW When the welding gun trigger is pressed an electrical current passes from the contact tube to the automatically fed electrode wire creating a small arc between the wire and the layers of base metal to be welded The heat from the arc melts the wire and fuses it together with the layers of base metal while flowing shielding gas isolates the weld from contaminants in the air Once it cools the wire and base metals are completely fused together at the joint creating one solid piece of metal i 023 Oh two three wire a special wire used for auto body repair is made of a high grade steel alloy that has a tensile strength of 70 000 pounds As it melts it helps fill in the joint adding strength to the weld 5 E To set up the MIG welder reference the operating manual to 1 set up the wire feed mechanism for 023 wire 2 hook the gas supply to the welder 3 set the gas regulator on the gas supply to control speed of the gas flow for 0 2 3 wire 4 set the amperage heat and voltage and wire speed for 0 2 3 wire b choose the polarity direction of cur rent and 6 plug the welder into a 110 or 220 grounded outlet BI Variables that affect the quality of a weld are travel speed travel direction and gun angle lI The seven basic types of weld joints are tack spot plug butt reinforced butt lap and a fillet weld WR The type of weld to use is determined by the location of the joint on the
13. present follow up activities to reinforce the program s key learning points As part of the 12 part series Auto Body Repair Dings and Scratches demonstrates the processes and techniques for repairing minor damage to sheet metal including how to identify and plan repairs procedures for performing repairs using various tools and supplies and tech niques for metal finishing After viewing this video and completing some of the learning activi ties included in this guide students will be better prepared to properly identify minor damage and develop and implement a repair plan for mending dents and scratches using the proper tools and techniques Use Dings and Scratches and the accompanying activities provided in this guide to prepare students for the most effective way to approach the repair of minor dents and scratches and to familiarize them with the tools and techniques they will most often use during the collision repair process LEARNING OBJECTIVES After viewing the program students will be able to E Demonstrate a basic knowledge of sheet metal repair operations and safety procedures BI Identify the correct tools to use given the task to be performed E Explain procedures for identifying damage and plans for repair of sheet metal E Explain procedures for repairing sheet metal panels E Follow proper procedures to repair damaged sheet metal EDUCATIONAL STANDARDS The primary certifying body for automotive technician training progr
14. steel Technicians can set up a MIG to weld metals other than steel such as aluminum but different wire shielding gas and settings are required according to the manufacturer s specifications O Technician A says that the primary purpose of the grounding cable from the welder is to complete the electrical circuit for the welder and enable the current to flow Technician B says that the primary purpose of the grounding cable from the welder is to hold parts that are being welded together so they don t move during the welding process Who is correct a Technician A b Technician B c Both A and B d Neither A nor B A a Feedback Grounding cable from the welder must be clamped to bare metal on the same panel that is being welded as close as possible to the weld point to complete the electrical circuit for the welder and enable the current to flow This grounding cable can be used to clamp the parts that are being welded together so they don t move during the welding process but that is not its primary purpose O Before welding on a vehicle auto body technicians should A Make a practice weld Feedback Before welding on a vehicle auto body technicians should make a practice weld on the same material and in the same position that will be used for the final weld 14 O Which of the following is a condition that occurs when the MIG welding gun is removed too quickly from the weld panel resulting in virtually no weld bead
15. the tool Used with a spot welder to pull out a dent spring hammering A dent repair technique that uses a dinging spoon held firmly against the back of a ridge or crease while a bumping hammer is used to hit the surface of the ridge to work down high spots and bump out low spots stud spot welder A welding gun that welds studs pins onto the surface of the dented metal panel used with a slide hammer that attaches to the studs and pulls out the dent surfacer A material that is used to fill in the fine grooves left from sanding which promotes the adhesion of the final finish weld on pulling tool A tool that is a variation of the slide hammer and dent puller two tools in one The slide hammer part of the tool is used to pull out the dent after the tip of the weld gun is actually welded to the dent This tool eliminates drilling holes in panels to pull dents PRE PROGRAM DISCUSSION QUESTIONS 1 What are some typical casues of minor panel damage to sheet metal on a car or truck 2 Have you ever painted a room If so describe the major steps in the painting process 3 How do the steps for painting a room relate to the repair of minor collision damage 4 What do you think might happen if a critical step is missed during the repair process 5 Today the repair of minor collision damage no longer includes drilling holes to pull out dents Why do you think this is the case 1 32778 Dings Auto Body TG 10 1 04 10 55 AM Page 8 F POST
16. CATIONAL STANDARDS The primary certifying body for automotive technician training programs is the National Institute for Automotive Service Excellence ASE ASE is a non profit organization estab lished in 1972 by the automotive industry to improve the quality of vehicle repair and service through the voluntary testing and certification of automotive repair technicians The National Automotive Technicians Education Foundation NATEF is a separate non profit foundation within ASE The mission of NATEF is to improve the quality of automotive technician training programs nationwide through voluntary certification The State Departments of Education in all 50 states support ASE NATEF certification of automotive programs National Standards This program correlates with the Program Certification Standards for Automobile Technician Training Programs from the National Institute for Automotive Service Excellence ASE and the National Automotive Technicians Education Foundation NATEF The content has been aligned with the following educational standards which reflect the tasks in the ASE Program Certification Standards for Automobile General Service Technician Programs 2 Copyright 2005 SHOPWARE Metal Welding lI Determine correct welding process in accordance with vehicle manufacturer s industry s recommendations GMAW MIG squeeze type resistance spot electrode wire type diameter and gas to be used in specific welding situations
17. a Full penetration b Burn through c Polarity d Shallow penetration A d Feedback Shallow penetration is a condition that occurs when the MIG welding gun is removed too quickly from the weld panel resulting in virtually no weld bead After grinding off the weld bead there is little left to hold these two pieces of material together resulting in a weak weld O What type of safety clothing and equipment should auto body repair professionals wear when performing welding tasks A Welding hood with 10 shade leather gloves non flammable long sleeves and pants without cuffs leather vests and work boots Feedback Proper safety clothing and equipment include a welding hood with 10 shade to protect against blinding light leather gloves to protect against metal cuts non flammable long sleeves and pants without cuffs that can trap sparks jumpsuit preferred leather vests for welding overhead and work boots O The type of weld to use is determined by the location of the joint on the vehicle and whether previous repairs were made to the repair area True or False A False Feedback The type of weld to use is determined by the location of the joint on the vehicle and whether the repair area is structural or non structural ADDITIONAL RESOURCES WEB SITES Auto Body Online www autobodyonline com Auto Body PI www autopi com frame htm Auto Body Pro www autobodypro com Auto Body Tool Mart Repair and Restoration Tutor
18. ail the proper way to store tanks hoses gauges and cutting brazing torches and the basics of testing lines for leaks attaching gauges to tanks and adjusting pressure settings to proper levels This program also discusses a variety of welding processes including MIG TIG and oxyacetylene and the most common concerns of welders including proper grounding of the machine and the work piece correct applications of commercial gases and maintaining weld tips Viewers will also realize the necessity of a positive attitude and concentration when performing welding tasks Safety First Welding Shop Safety is one of a four part series that explains the need for safe ty procedures as well as precautions that can be taken to ensure a safe working environ ment The series also includes Electrical Safety Safety First Woodworking Safety and Safety First Auto Shop Safety Order 14465 http www cambridgeeducational com 1 800 468 4227 18 SHOPWARE 2572 Brunswick Pike Lawrenceville NJ 08648 www shopware usa com Call Toll Free 800 487 3392 32777 32778 Dings Auto Body TG 10 1 04 10 55 AM Page 1 F AUTO BODY REPAIR DINGS AND SCRATCHES TEACHER S GU SHOPWARE 32778 Dings Auto Body TG 10 1 04 10 55 AM Page 2 F INTRODUCTION This Teacher s Guide provides information to help you get the most out of Dings and Scratches The contents in this guide will enable you to prepare your students before using the program and
19. ams is the National Institute for Automotive Service Excellence ASE ASE is a non profit organization established in 1972 by the automotive industry to improve the quality of vehicle repair and service through the vol untary testing and certification of automotive repair technicians The National Automotive Technicians Education Foundation NATEF is a separate non profit foundation within ASE The mission of NATEF is to improve the quality of automotive technician training programs nationwide through voluntary certification The State Departments of Education in all 50 states support ASE NATEF certification of automotive programs National Standards This program correlates with the Program Certification Standards for Automobile Technician Training Programs from the National Institute for Automotive Service Excellence ASE and the National Automotive Technicians Education Foundation NATEF The content has been aligned with the following educational standards which reflect the tasks in the ASE Program Certification Standards for Automobile General Service Technician Programs 2 Copyright 2005 SHOPWARE EH 32778 Dings Auto Body TG 10 1 04 10 55 AM Page 3 F Outer Body Panel Repairs Replacements and Adjustments E Determine the extent of the direct primary and indirect secondary damage and the direc tion of impact plan the methods and order of repair E Remove and replace bolted riveted bonded and welded panels repair we
20. are a scavenger hunt list for the Scouts Based on the clues provided in this description create a comprehensive list of tools and supplies that you will need to repair the minor damage You may consult several sources to help you create the list such as the Dings and Scratches video the Internet collision repair magazines etc Top Ten After roughing out the damaged areas and returning them as close as possible to the vehicle s original contours the second phase in the minor collision repair process is preparing the sur face of the metal panel in preparation for the final finish Surfacing material must be applied using a variety of tools and supplies as well as specific techniques for the given material Prepare a list of The Top Ten Things Auto Body Repair Technicians Should Do During Metal Surface Preparation Think about safety rules as well as guidelines for mixing and applying materials such as body filler primer and putty Step 10 should be the first step in the surface preparation process Step 9 should be the second step and so forth Step 10 is provided below to get you started 10 To remove all dirt grime wax grease road tar and any silicone from automotive waxes the auto body repair technician should clean the surface using soap and water and then dry the area with a clean cloth Preliminary Steps Pamphlet Conscientious auto body repair technicians know the four Ps of approaching repairs Prior Planning Prevents
21. aspect of welding What is a typical day like for you What if any new technologies or equipment are being introduced that will improve the quality of weld joints and or the welding process in general After completing your research prepare a presentation about your discussion with the auto body repair technician You may share your findings with the class by presenting an oral report or a PowerPoint presentation Welding Technology The video described the MIG welding process and why it s the most popular choice for colli sion repair The buzz today is about new welding technologies involving laser and automated welding Research new welding technologies on the horizon using the Internet including Discussion Forums or reference industry publications automotive welding professionals etc and write a brief one page paper about the potential advantages and disadvantages of the new technologies over the MIG welding process INTERNET ACTIVITIES Scavenger Hunt There are various resources on the Internet that provide information about welding in an auto body repair environment Using a search engine type in key words that will help you find cur rent information and Web sites that are useful to your search Some search terms you may want to use to get started include welding basics and MIG welder Create a handout on five of the web sites you found This handout should list the Web sites related to automotive welding and a brief d
22. e following materials is used to fill surface pinholes and deep scratches that cannot be buffed out a Glazing putty b Sprayable polyfiller c Bogy filler d Both A amp B 11 32778 Dings Auto Body TG 10 1 04 10 55 AM Page 12 F A d Feedback Glazing putty is used to fill fine pinholes Sprayable polyfiller is used to fill in pin holes and minute scratches not suitable for body filler or glazing putty Q Which hand tool is used in conjunction with a dinging spoon to work down high spots and bump out low spots during the spring hammering process a Dent puller b Bumping hammer c Slide hammer d Stud spot welder A b Feedback The spring hammering process is a dent repair technique that uses a dinging spoon held firmly against the back of a ridge or crease while a bumping hammer is used to hit the surface of the ridge to work down high spots and bump out low spots Q When mixing filler and hardener together on the filler mixing board why should auto body repair technicians use a back and forth scraping motion rather than stirring the mixture A Stirring the mixture causes air bubbles to form Feedback When combining filler and hardener mix the filler and hardener together using a back and forth scraping motion Stirring the mixture will cause air bubbles to form Air in the compound will result in the filler curing unevenly Q Auto body repair technicians should only mix body filler and hardener compounds
23. earn points The player who answered the previous question correctly will select a new category and amount If the question was answered incorrectly the other team will select a new category and amount The game continues in this fashion until all questions have been answered The team with the most points wins Welding Considerations Checklist As a group prepare a checklist of considerations auto body repair technicians should initially think about when planning a weld Consult the Welding video the Internet and any other sources that you have available Think about different welding tasks and create a checklist of factors auto body repair technicians should consider before beginning a welding task Consider the following topics MIG welder set up Joint location Structural vs Non structural Weld Task Steps Types of Weld Joints and when to use them Pre preparation of Steel Material Safety Precautions 10 Create a one page job aid in the form of a checklist that lists pre welding considerations to help apprentice auto body repair technicians prepare for a welding task For example the checklist could include the following items noting tasks and sub tasks O Setup the MIG welding gun for steel according to the operating manual specifications O Setup the wire feed mechanism for 023 wire Create a logo or insert graphics to jazz up the job aid Include blanks check boxes for addi tional tasks to be filled in late
24. eceived to your post What have you learned from reading other posts Did any of the responses con flict with one another If so what issues did they raise ASSESSMENT QUESTIONS O Technician A says that oxyacetylene welding has limited use in collision repair Technician B says that MIG welding is the only ideal welding process for collision repairs Who is correct a Technician A b Technician B c Both A and B d Neither A nor B A c Feedback MIG welding is used for general collision repairs because it concentrates the heat in a narrow area and the welds achieve100 percent fusion Oxyacetylene welding can also be used in the collision repair process but it is limited to metal cutting fastener removal and heat cleaning Because it s slower than MIG welding it s a good choice for practice in getting used to the welding process O Which one of the following variables does NOT affect the quality of a weld a Weld penetration b Travel speed c Travel direction d Welding gun angle A a Feedback Variables that affect the quality of a weld are travel speed travel direction and gun angle Weld penetration is related to travel speed caused by moving the MIG welding gun too fast too slow just right or holding the gun in place for too long There are varying degrees of penetration O When conducting destructive testing to determine the strength and penetration of the weld which one of the following is characte
25. elders should practice making weld joints and then destroying them Destructive testing is intended to determine the strength and penetration of the weld to see if it was done correctly A good weld joint is one that tears apart when destroyed a weak weld joint is one that simply breaks apart with little or no tearing VOCABULARY TERMS amperage The voltage on the MIG welder that typically uses the wire feed speed to control the amount of heat at the arc Since the heat remains relatively constant the weld beads pro duced are usually uniform in shape and size Current is another name for amperage argon gas An inert gas found in shielding gas used in MIG welding that protects the weld from contaminants Typically combines with the steel in the joint and makes a stronger clean er weld burn through A condition that occurs when the welding gun is moved too slowly or held in place for too long causing the weld bead to melt too far down into the joint and burn through the other side of a steel panel which reduces the strength of the weld joint The 6 slower the weld gun is moved the deeper the weld penetration butt weld A type of weld that is used to join two metal parts aligned in the same plane butting up against one another by filling the gap between the two metal parts contact tube A tube on a welding gun usually made of copper or copper alloy that con ducts electricity direct current An electrical current that f
26. escription of the reasons why you would recommend them to your fel low classmates Automotive Certification Research The primary certifying body for automotive technician training programs is the National Institute for Automotive Service Excellence ASE The National Automotive Technicians Education Foundation NATEF is a separate non profit foundation within ASE Both entities have a specific purpose regarding automotive technician training programs nationwide Using a search engine such as Yahoo or Google research each organization Then write a one page summary of your findings regarding the mission history fundamentals and benefits of each organization Be prepared to discuss your findings with the class 12 Discussion Forums Visit www autobodyonline com and enter the discussion forums by clicking the Discussion tab in the upper left corner of the web page Post a question about welding techniques weld joints or the MIG welding gun Ask about the nuances that experienced auto body repair technicians should be aware of when approaching welding for the first time Also review the other posts within the forums and see if you can gather any other information about welding in the collision repair business After a week copy all your responses as well as any other posts you have seen that are relevant into a word processing document Then answer the following questions What have you learned as a result of the answers you have r
27. fixing cars and trucks they can become service managers service engineers automotive writers or even auto technology teachers Order 24924 www cambridgeeducational com 1 800 468 4227 Introduction to Welding VHS DVD Meridian Education This four part live action series introduces viewers to four major welding areas Oxyfuel Shielded Metal Arc Gas Tungsten Arc and Gas Metal Arc Flux Core Arc Each video includes welding definitions welding components safety equipment assembly and use of the system and the types and kinds of welds Safety procedures are emphasized throughout including the proper clothing equipment and filter lens required for the job This series pro vides an excellent overview of the welding field and clearly demonstrates proper technology in each area Order 25686 http www meridianeducation com 1 800 727 5507 Metal Shop Safety VHS DVD Meridian Education This program is a fast paced informative video that demonstrates the kind of precautions that should be taken when working with metals Sheet metal work soldering welding foundry work forging and general safety are summarized Footage of actual fatal accidents is used to strengthen the importance of safety in the metals lab Watch what happens when molten metal is spilled on water when it explodes and when molten aluminum is spilled on a non protective tennis shoe This metal working safety video should be viewed by anyone studying technology or
28. g A process of applying heat to two pieces of metal to fuse them together Often additional filler material from a wire or rod is added to help complete the weld joint weld puddle The accumulation of molten welding metal within a weld joint PRE PROGRAM DISCUSSION QUESTIONS 1 What is welding Why is it used And what does it accomplish 2 Have you seen someone weld something either in person or on television If so what were they welding What type of tools and equipment were they using 3 Many of the things we use in our daily lives are welded or made with welding equipment What are some everyday items or structures that are constructed using a welding process 4 What welding equipment is used when performing collision repairs 5 Safety is important when performing welding tasks What safety measures should welders practice within the auto body repair shop POST PROGRAM DISCUSSION QUESTIONS 1 Now that you have seen the Welding video explain why MIG welding is the ideal welding process for collision repairs 2 What are the three variables that affect the quality of a weld 3 As a group list the seven basic types of weld joints and identify when each one is used 4 What are some of the considerations welders should think about when planning a weld 5 In your opinion what is the most critical element of perfecting the art of welding GROUP ACTIVITIES What s Wrong With This Picture Using poster paper sketch
29. glance to see that today s cars have more in common with the space shuttle than they do with the horseless carriage of a century ago This no nonsense 16 piece poster set will help students quickly and easily develop a familiarity with the many complicated sub systems common to domestic and foreign cars Correlates to the National Automotive Technicians Education Foundation NATEF standards for automotive technology Order 31098 www meridianeducation com 1 800 727 5507 15 32778 Dings Auto Body TG 10 1 04 10 55 AM Page 16 T SHOPWARE 2572 Brunswick Pike Lawrenceville NJ 08648 www shopware usa com Call Toll Free 800 487 3392 32778
30. ials www autobodytoolmart com restorations html 15 Automotive Body Repair News www abrn com abrn Auto Glossary www autoglossary com Collision Repair Industry Insight http www collision insight com How Stuff Works Auto Stuff Page http auto howstuffworks com l car www i car com National Automotive Service Task Force www nastf org National Automotive Technicians Education Foundation www natef org Tektips Auto Body Pro Website www autobodypro com tektips htm The Welding Institute http www twi co uk j32k index xtp Welding http www welding com BOOKS Duffy James E CAR Professional Automotive Collision Repair Albany NY Delmar Thomson Learning 2001 ISBN 0766813991 Duffy James E Auto Body Repair Technology 4th Edition Clifton Park NY Thomson Delmar Learning 2003 ISBN 0766862747 Killingsworth Jeff Eric Godfrey and John H Haynes The Haynes Suspension Steering And Driveline Manual Newbury Park CA Hayes North America 1998 ISBN 1563922932 OTHER PRODUCTS Automotive Technicians VHS DVD Cambridge Educational Sponsored by the National Automotive Technicians Education Foundation NATEF this pro gram explores automobile repair and collision repair NATEF works closely with Automotive Service Excellent ASE the nation s only industry wide certification program for automotive technicians Technicians with a sound education have a choice of career avenues Aside from
31. inst the metal while striking the opposite side with light hammer blows This technique requires that both the hammer head and dolly surface match the desired shape of the panel If the area is flat a flat dolly and hammer should be used If the area is curved both the dolly and hammer head should match the curve as closely as possible pick A tool that is often inserted into an existing hole to push or pry up metal in areas that can t be reached with spoons often used in place of a pry bar polyfiller Liquid body filler consisting of two parts the base filler and the hardener which is sprayed on to fill in all of the pinholes and minute scratches for which bogy filler or glazing putty is not suitable primer A material that is applied over bare metal to promote the adhesion of surfacer material Failure to prime bare metal areas often results in the paint peeling off later pry bar A tool that is often inserted into an existing hole to push or pry up metal in areas where there is limited access to the back panel or where the area cannot be reached with spoons often used in place of a pick rough out The process of lowering high spots and raising low spots to return them as close as possible to the vehicle s original contours shrinking hammer A tool used to shrink metal in a raised area to restore the original contour slide hammer and dent puller A metal rod with a tool at one end and a heavy weight that slides on the rod to pull or push
32. ionships lI Use the service manual to identify the manufacturer s specifications for system parameters operation and potential malfunctions BI Supply clarifying information to customers associates parts supplier and supervisors Technology Standards The activities in this Teacher s Guide were created in compliance with the following National Education Technology Standards from the National Education Technology Standards Project The content has been aligned with the following educational standards and benchmarks lI Use a variety of media and formats to communicate information and ideas effectively to mul tiple audiences lI Use telecommunications to collaborate publish and interact with peers experts and other audiences ll Use productivity tools to collaborate in constructing technology enhanced models prepare publications and produce other creative works lI Use technology tools to enhance learning increase productivity and promote creativity ll Use technology to locate evaluate and collect information from a variety of sources The National Education Technology Standards reprinted with permission from the International Society for Technology Education PROGRAM OVERVIEW The majority of auto body repairs fall under the category of minor damage specifically dings and scratches Usually these damages are too extensive to simply fill in with body filler but are too small to require a new panel This video shows how to
33. is primer applied to bare metal before applying any other surface materials A Primer promotes adhesion of surface materials Feedback H bare metal is showing it must be primed before surface materials such as sur facer or paint are applied Primer promotes adhesion of the surface materials If bare metal areas are not primed there is the risk of paint peeling off later O A damaged area should be within 1 4 of an inch of the original contour before applying any body filler True or False A False Feedback Roughing out the damaged areas is the process of returning them as close as possible to the vehicle s original contours by lowering high spots and raising low spots The area should be within 1 8 of an inch of the original contour before applying any body filler ADDITIONAL RESOURCES WEB SITES Auto Body Online www autobodyonline com Auto Body P I www autopi com frame htm Auto Body Pro www autobodypro com Auto Body Tool Mart Repair and Restoration Tutorials www autobodytoolmart com restorations html Automotive Body Repair News www abrn com abrn Auto Glossary www autoglossary com 13 32778 Dings Auto Body TG 10 1 04 10 55 AM Page 14 F Automotive Services Association www asashop org Automotive Youth Educational Systems AYES www ayes org index asp Collision Repair Industry Insight http www collision insight com How Stuff Works Auto Stuff Page auto howstuffworks com l car www i car com
34. ks Students will learn the primary parts of the welder and the function of each component and the ways in which travel speed direction and gun angle affect the quality of a weld Topic 3 Types of Weld Joints and Welding Techniques This section of the program describes types of weld joints and how to form them using the welding gun Students will learn the factors that determine when to use each type of weld joint Topic 4 Practice Welds and Destructive Testing This section of the program describes the importance of practicing welding techniques and the destructive testing method used to determine the quality of the weld Topic 5 Safety Practices In this section students will learn the significance of protective clothing and the necessary pre cautions to take when performing welding tasks to avoid bodily injury and damage to nearby property FAST FACTS lI Welding is a process where heat is applied to two pieces of metal to fuse them together In many cases additional filler material from a wire or rod is added to help complete the weld joint lI Most of today s vehicle frames are built in one piece called a unibody which is construct ed by welding bolting and adhesive bonding the various body parts together BI MIG welding is the ideal welding process for collision repairs because it concentrates the heat in a narrow area the welds performed on unibody frames during collision repairs must achieve100 percent fusion in order to
35. ld or replace lI Check and adjust clearances of front fenders header and other panels lI Restore contours of damaged panel to a surface condition suitable for metal finishing or body filling BI Apply protective coatings and sealants to restore corrosion protection E Repair or replace plastic panels Metal Finishing and Body Filling lI Remove paint and other materials from the damaged area of the body panel lI Cold shrink stretched panel areas to proper contour lI Metal finish the damaged area of a body panel to eliminate surface irregularities E Prepare surface for application of body filler material BI Mix and apply plastic body filler shape during curing lI Sand cured plastic body filler to contour 2004 Automobile Program Standards by the National Institute for Automotive Service Excellence ASE Copyright 2004 Reprinted with permission Language Arts and Communication Standards According to ASE NATEF standards the automobile technician must be proficient in the fol lowing Language Arts and Communications related academic skills that are embedded in the occupation The activities and information presented in this program and accompanying teacher s guide are aligned to the following standards from the National Automotive Technicians Education Foundation from the National Institute for Automotive Service Excellence E Request collect comprehend evaluate and apply oral and written information gathered from customer
36. lly feeds wire the metal through the welding tip into the weld while using shielding gases to protect the metal against corrosion during the welding process MIG welding is ideal for collision repair on high strength steel because it happens in a microsecond preventing the metal surrounding the weld joint from heating up and because it achieves 100 percent fusion Can be used to weld metals other than steel such as aluminum but requires different wire shielding gas and settings 023 oh two three wire A type of special wire that is made of a high grade steel alloy that has a tensile strength of 70 000 pounds As it melts it helps fill in the joint adding strength to the weld 023 wire can be used on all thicknesses of steel during auto body repairs oxyacetylene welding A fusion welding process which uses a mixture of oxygen and acety lene gas that is slow to reach the melting temperature of steel but heats up the metal in areas adjacent to the weld causing warping and loss of structural strength For this reason it is no longer recommended for most collision repairs but can be used for metal cutting fas tener removal and heat cleaning plug weld A type of weld that is used to weld two or more base metals together by drilling small holes 8 millimeters to 21 4 inch that get progressively smaller and filling them with short bursts from the outside working inward to ensure fusion of each layer polarity The direction of the flow of
37. lows in one direction only electrode wire Part of the welding gun that must be in contact with the base metal to com plete the electrical circuit and start the welding process fillet weld A type of weld that joins two pieces at right angles to one another with a continu ous weld bead or with spot welds full penetration A condition that occurs when the MIG welding gun is held in place just long enough causing the weld fusion to penetrate through the full thickness of the base metal but not so far as to burn through the other side Typically characterized by a low profile weld bead fusion Heating materials to be joined to their melting point so that the molecules of the met als actually combine gas nozzle A component that fits on the tip of the welding gun which directs the flow of shielding gas to the weld gas regulator Component on the gas supply that controls the speed of the shielding gas flow in MIG welding inert Not combining readily with other elements a property of argon gas lap weld A type of weld that is formed when two pieces of metal overlap and are welded together front and back by running a continuous weld bead or spot welds along the joints stitch a weld A technique used to prevent metal from overheating by pausing between welds to allow the metal to cool metal inert gas MIG welding Also called gas metal arc welding or wire feed welding A type of gas metal arc welding process that automatica
38. made by the same manufacturer True or False A True Feedback Body filler should only be mixed with hardener that is made by the same manufac turer to ensure compatibility of both compounds Q Technician A says that a stud spot welder and studs should be used in conjunction with a slide hammer and dent puller to pull out a dent when there is no access to the back of the panel Technician B says that when using a stud spot welder it is not necessary to remove paint before welding the stud to the dent Who is correct a Technician A b Technician B c Both A and B d Neither A nor B A a Feedback A stud spot welder and studs are used in conjunction with a slide hammer and dent puller to pull out a dent when there is no access to the back of the panel However before welding the stud to the dent you must remove the paint in the damaged area Q A n helps auto body repair professionals to organize both the parts and supplies needed for an upcoming repair and the process that follows so no critical steps are missed A repair plan Feedback A repair plan is essential to a successful repair job 12 p 32778 Dings Auto Body TG 10 1 04 10 55 AM Page 13 F Q Which hand tool should be used to push or pry up metal in areas that cannot be reached with spoons A A pick Feedback Picks can often fit through existing holes eliminating the need to remove interior trim or panels to reach the damaged area Q Why
39. ng and installing a replacement is a very time consuming task taking 12 to 14 hours plus the cost of the replacement part Repairing rather than replacing is often a time and money sav ing option E After examining and assessing the extent of damage auto body repair technicians should develop a detailed step by step repair plan to identify and organize the parts and supplies needed prior to beginning repairs and to organize the repair process so no critical steps are overlooked II Practice proper safety precautions to avoid bodily injury and property damage Wear protec tive safety glasses and have a dust mask handy Protect undamaged areas adjacent to the repair by covering windows or removing and storing trim and other parts near the repair area 32778 Dings Auto Body TG 10 1 04 10 55 AM Page 6 F E Roughing out the damaged areas means to return them as close as possible to the vehi cle s original contours by lowering high spots and raising low spots The area should be within 1 8 of an inch of the original contour before applying any body filler E Roughing out a damaged area usually requires gaining access to the backside of the dam aged panel by removing interior panels and hardware E f damage is minor and there is enough access to the back side of the panel use body hammers dollies and spoons II f damage is minor and there is limited access to the back panel use body picks or pry bars E f there is no access to the back
40. ng levels of accessibility Topic 4 Basic Metal Finishing Techniques This section of the program demonstrates basic techniques for preparing the surface of metal panels using a variety of supplies and tools Students will learn safety rules and guidelines for mixing and applying various types of body filler primer and putty in preparation for the final finish FAST FACTS lI Most auto body repairs fall under the category of minor damage dents and dings too big to fill but too small to need a new panel As a result the repair of minor panel damage to sheet metal is probably the most common task auto body repair technicians will encounter in collision repair E Before beginning any repair auto body repair technicians must assess the extent of the damage by looking at the point and direction of impact to determine the starting point for the initial inspection Some damaged parts may have to be removed to determine indirect damage to parts that are not immediately visible Areas to note are scrapes buckling and panel misalignment or movement E Drilling holes to pull out dents is no longer an accepted practice for dent repair II The repair or replacement of damaged panels is determined by estimating the length of time it will take to remove and replace the damaged panel plus the cost of a replacement part compared to the amount of time for panel repair lI For some parts such as quarter panels which are welded or bonded into place removi
41. of the panel use a spot welder stud with a slide hammer and dent puller E The surface of the hammer and the dolly should match as closely as possible the original contours of the panel being repaired Heavier hammers should be used for roughing out while lighter finishing hammers should be used for final shaping lI When grinding off any remaining paint weld scale or corrosion in a patch area in prepara tion for a spot weld and remove paint from the damaged area and 3 to 4 inches around it while trying to remove as little of the metal as possible lI Dents should be roughed out within 1 8 inch of the original contour lI Use of a stud spot welder during minor collision repairs eliminates the need to punch or drill a hole in the panel Holes destroy rust proofing and provide an ideal spot for corrosion to set in lI Proper surface preparation is critical to the success of body filler adhesion and includes removal of all dirt grime wax grease road tar and any silicone from automotive waxes VOCABULARY TERMS body filler Durable filler consisting of two parts the base filler and the hardener which is used to fill low spots within 1 8 inch or less of the original surface contour body filler mixing board A board made of glass plastic or metal used to mix body filler body hammer A tool used for shrinking high areas of sheet metal to level the surface to its original contour by starting with light blows on the edge and working towa
42. or supply is used procedures or techniques for use safety considerations etc Participants may use the Internet reference the Dings and Scratches video consult the instructor etc to gather infor mation After all information is gathered play What s My Line as follows One three person group forms a panel in the front of the room panel members are referred to as 1 2 and 3 During a defined period of time the class asks the panel questions that require a YES or NO response to try to determine which tool or supply the panel represents For example if the panel has assumed the identity of hardener the class could ask Are you used to pull out a dent No Do you play a part in the surface preparation process Yes Are you used to apply finishing material No Do you come in a can No Do you come in a tube Yes Are you always used with other compatible material Yes After the time is up the instructor asks participants to write down the identity tool or supply of the panel before calling upon a volunteer to reveal his her guess After correctly revealing the identity of the panel another three person group forms the next panel The game is played 8 E 32778 Dings Auto Body TG 10 1 04 10 55 AM Page 9 F until all students have appeared on a panel Note The instructor will know the identity of each panel and preside over the questioning period guiding students when necessary Tool Time
43. r by students Be prepared to share your checklist with the class Optional Make copies of the checklist and distribute to fellow classmates INDIVIDUAL STUDENT PROJECTS Welding Joints Match Game The Welding video describes the following seven basic types of weld joints Tack Spot Plug Butt Reinforced Butt Lap and Fillet Obtain two pieces of poster board On one poster board at approximately three inches down from the top draw two columns of the same size and then divide these columns into eight rows Label the first row in the left column Weld Joint and label the first row in the right column Description Using the second piece of poster board cut out and glue tape a rectangle in each row in the right column to form a pocket for a total of seven pockets Letter the pockets A through G Research the types of weld joints using the Internet or library resources Then draw and identi fy a simple picture of each type of weld joint in the left column Using the second piece of poster paper cut out seven squares that are slightly smaller than the pockets For each weld joint briefly describe its purpose and or when it should be used without identifying the weld joint by name For example a description for a tack weld joint might read This type of weld joint uses small weld beads to temporarily hold the pieces of sheet metal in place until the final welds are made Enables the welder to determine if all pieces fit The object of the game is
44. rd the middle bumping hammer A tool used in conjunction with a dinging spoon to work down high spots and bump out low spots during the spring hammering process bubbles Air trapped in body filler caused by excessive stirring dent puller A tool that is used with a slide hammer and a spot welder to pull out a dent when interior trim or body panels prevent access to the backside of the damaged panel dinging spoon A tool used to smooth out and level dings low spots when the back of the panel is not easily accessible with a dolly When held against the ridge of a dent and struck with a hammer this tool spreads the blow over a large area disc sander A tool that uses sandpaper to grind off remaining paint weld scale or corrosion in a patch area dolly A large chunk of steel with a slightly curved flat side to pound against glazing putty Fine filler consisting of two parts the base filler and the hardener which is used to fill in scratches that cannot be buffed out 32778 Dings Auto Body TG 10 1 04 10 55 AM Page 7 F hammer off dolly A technique for roughing out a large buckle by placing the dolly under a low spot while striking an adjacent high spot with the hammer This action causes the hammer to drive the high spot down while the rebounding dolly drives the low spot up without stretch ing the metal hammer on dolly A technique for straightening metal by holding the dolly directly behind the high spot and firmly pressing it aga
45. ristic of a good weld joint a The weld joint breaks apart with little or no tearing b The weld joint tears apart when destroyed c The weld joint is invisible to the naked eye d The weld joint crumbles in tiny pieces 13 A b Feedback Apprentice welders should always practice making weld joints and then destroy ing them Destructive testing is intended to determine the strength and penetration of the weld to see if it was done correctly A good weld joint is one that tears apart when destroyed a weak weld joint is one that simply breaks apart with little or no tearing O Which component on the gas supply controls the speed of the shielding gas flow in MIG welding a Gas nozzle b Gas regulator c Electrode wire d Contact tube A b Feedback The gas regulator is the component on the gas supply that controls the speed of the shielding gas flow in MIG welding The gas nozzle electrode wire and contact tube are parts of the welding gun that are not related to the speed of the shielding gas flow on the gas supply O Once the MIG welder is properly set up auto body repair technicians should not have to alter the settings for collision repair as long as they are welding steel True or False A True Feedback Most work in collision repair involves welding steel Once the MIG welder is properly set up auto body repair technicians should not have to alter the settings for collision repair as long as they are welding
46. roblem resolu tion and the results of the work performed for the customer or manufacturer BI Follow all oral written directions that relate to the task or system under study E Comprehend and apply industry definitions and specifications to diagnose and solve problems in all automotive systems and components of the automobile and light truck ll Comprehend and use problem solving techniques and decision trees that are contained in service manuals and databases to determine cause and effect relationships ll Use the service manual to identify the manufacturer s specifications for system parame ters operation and potential malfunctions BI Supply clarifying information to customers associates parts supplier and supervisors Technology Standards The activities in this Teacher s Guide were created in compliance with the following National Education Technology Standards from the National Education Technology Standards Project The content has been aligned with the following educational standards and benchmarks lI Use a variety of media and formats to communicate information and ideas effectively to multiple audiences E Use telecommunications to collaborate publish and interact with peers experts and other audiences lI Use productivity tools to collaborate in constructing technology enhanced models pre pare publications and produce other creative works lI Use technology tools to enhance learning increase productivity and promote
47. s associates and supervisors regarding problem symptoms and potential solutions to problems BI Identify the purpose for all written and oral communication and then choose the most effec tive strategies for listening reading speaking and writing to facilitate the communication process E Adapt a reading strategy for all written materials e g customer s notes service manuals shop manuals technical bulletins etc relevant to problem identification diagnosis solu tion and repair lI Use study habits and techniques i e previewing scanning skimming taking notes etc when reviewing publications shop manuals references databases operator s manuals and text resources for problem solving diagnosis and repair WE Write clear concise complete and grammatically accurate sentences and paragraphs lI Write warranty reports and work orders to include information regarding problem resolution and the results of the work performed for the customer or manufacturer BI Follow all oral written directions that relate to the task or system under study 32778 Dings Auto Body TG 10 1 04 10 55 AM Page 4 F lil Comprehend and apply industry definitions and specifications to diagnose and solve prob lems in all automotive systems and components of the automobile and light truck lil Comprehend and use problem solving techniques and decision trees that are contained in service manuals and databases to determine cause and effect relat
48. s removed too quickly from the weld panel There is virtually no weld bead After grinding off the weld bead there is little left to hold these two pieces of material together resulting in a weak weld shielding gas A type of gas that flows through a MIG weld gun tip during the welding process that isolates the weld from contaminants in the general atmosphere C 25 shielding gas is a 75 25 mixture of argon and carbon dioxide that is typically used in MIG welding simple butt weld A variation of a butt weld that is formed by holding the weld gun at a 90 degree angle and moving it along the joint to create one continuous weld Is most often used in areas that do not require structural strength sectioning repairs on rocker panels and door posts spot weld A type of weld that is used to fuse the top metal to the bottom without pre drilling a hole A spot weld is made by holding the welding gun at a 90 degree angle from the base metals to be welded This weld type is not strong or consistent tack weld A type of weld that uses small weld beads to hold the pieces of metal in proper alignment temporarily until the final welds are made Enables the welder to determine if all pieces fit tungsten inert gas TIG welding A type of gas metal arc welding process that is often used in engine repair weld bead A weld deposit produced by a single pass during one of the welding processes weld joint The joining of two or more metal parts by welding weldin
49. ssfully used in the past Also review the other posts within the forums and see if you can gather any other information about preliminary steps safety considerations proper procedures surface preparation etc After a week copy all your responses as well as any other posts you have seen that are rele vant into a word processing document Then answer the following questions What have you learned as a result of the answers you have received to your post What have you learned from reading other posts Did any of the responses conflict with one another If so what issues did they raise ASSESSMENT QUESTIONS O Technician A says that the hammer off dolly method to rough out a large buckle is per formed by placing the dolly under a low spot while the hammer is applied to a high spot just to the side of the dolly Technician B says that the hammer off dolly technique raises the low spot and lowers the high spot simultaneously without stretching the metal Who is correct a Technician A b Technician B c Both A and B d Neither A nor B A c Feedback The hammer off dolly method to rough out a large buckle is performed by placing the dolly under a low spot while the hammer is applied to a high spot just to the side of the dolly This technique raises the low spot and lowers the high spot simultaneously without stretching the metal which is why the hammer off dolly method works well to rough out a large buckle O Which one of th
50. te one repair related question on one side of the card and the corresponding answer on the back Collect the completed cards from each team and place them in two separate boxes one box for each team Instruct each team to choose five players to form a panel Appoint an audience member to keep score during the game Each player will take turns choosing a question submitted by the other team from the box The first player on one team will give the instructor the chosen card The instructor will read the question and the player will attempt to answer it If a player answers correctly a point is awarded to his her team Likewise if a player answers incorrectly a point is subtracted Any audience member may then attempt to answer questions that were answered incorrectly but no points will be awarded The instructor will announce the winner after all questions have been read 9 32778 Dings Auto Body TG 10 1 04 10 55 AM Page 10 F INDIVIDUAL STUDENT PROJECTS Prepare a Scavenger Hunt List Your car has just suffered minor damage to the left quarter panel Fortunately there is enough access to the back side of the panel to make repairs You have determined that repair is more economical than replacement You have solicited the help of Boy Scouts to conduct a scav enger hunt in order to gather the tools and supplies needed to rough out the damaged area and prepare the surface of the panel in preparation for the final finish You must prep
51. the area of an auto body repair shop where welding tasks are performed Title the poster heading What s Wrong With This Picture Using the safety pre cautions that were presented in the video include 8 10 examples of dangerous procedures or inadequate safety measures For example draw a welder who is not wearing the proper clothing or welding hood You may research welding safety measures online for additional ideas Color the poster using colored markers or pencils Present the poster to the class by asking the students to inspect the poster in groups of three and to write down their obser vations Stress that this exercise is to be done silently After all students have had the oppor tunity to study the poster and record their findings ask volunteers to name one observation on their list until all examples of inadequate safety measures have been revealed Design a Ouiz Show Game As a group prepare five questions and their corresponding answers related to the following four categories MIG Welder Set Up Weld Joints Welding Techniques Safety Practices there will be a total of 20 questions and answers Assign a point value to each of the five questions within each category ranging from 100 to 500 points The level of difficulty should increase with the point value Designate individuals to play the role of the MC Scorekeeper and Game Technician The MC will read the game instructions categories questions and make final determina
52. tions of the accuracy of each response the Scorekeeper will keep score by adding and subtracting points and the Technician will either navigate within the computer based gaming application or in the case of a non computer format the Technician will erase the point value of each question on the board to indicate the question was chosen Option 1 Create a PowerPoint presentation that includes the questions answers and point values You can consult a Web site to access a PowerPoint template designed for this type of game http languagecenter cla umn edu index php page forum jeopardy Option 2 Draw the game board on the chalkboard as shown below MIG Welder Set Up Weld Joints Welding Techniques Safety Practices 100 100 100 200 200 200 300 300 300 400 400 400 500 500 500 500 Instructions Divide the class into two teams and instruct each team to choose a name Write the team names on the chalkboard for scorekeeping purposes The instructor will select and read aloud the 100 question in the first category to begin the game The first person to raise his her hand on either team will be given the opportunity to answer the question e H a player answers a question correctly his her team will earn points Likewise if a player answers a question incorrectly his her team will lose points Any team member will be permitted to answer questions that were initially answered incor rectly but neither team will
53. to match each description to the correct welding joint by placing the correct descriptive card in the pocket that is located across from the corresponding graphic Write the letter of the weld joint on the BACK of each descriptive card to indicate its correct matching pocket Again using the second piece of poster paper create a large pocket that is capable of holding all of the descriptive cards Attach this pocket to the bottom of the first poster to store the cards At the top of the poster write brief instructions for playing the game Invite classmates to challenge themselves by playing the Welding Joints Match Game Interview a Welder What is a typical day like for a welder One way to learn about the profession is to visit a local auto body repair shop and speak with an experienced auto body repair professional Contact call or visit a local auto body repair establishment and ask if they could arrange a 15 minute interview for you to speak with an auto body repair professional who has compre hensive experience in the field of welding Inform them of the purpose of your request 11 Prepare a set of open ended questions to ask the auto body technician during the interview You may use the following questions Which welding technique or weld joint is easy to master and why Which is hard to master and why What aspects of MIG operation do new welders often overlook In your opinion what do you think is the most challenging
54. vehicle and whether the repair area is structural or non structural E The steps to prepare for a weld are 1 prepare the surface by removing paint under coatings rust dirt oil and grease 2 apply a weld through primer to the surfaces to be welded and areas immediately adjacent to protect against corrosion in weld zones and 3 chemically clean the area to be welded E Since MIG welders reach a temperature approaching 9 000 degrees Fahrenheit and pro duce ultraviolet light the same light that causes sunburn proper protection is critical E Proper safety clothing and equipment include a welding hood with 10 shade to protect against blinding light leather gloves to protect against metal cuts and sparks non flamma ble long sleeves and pants without cuffs that can trap sparks jumpsuit preferred leather vests for welding overhead and work boots Wi Practice safety in the shop by covering adjacent equipment and car parts to protect prop erty from flying sparks E Practice safe MIG welder operation by avoiding wet floors checking fraying on cords cables keeping the welder within reasonable distance of the welding site and ensuring the MIG set up follows all operator manual specifications BI The grounding cable from the welder must be clamped to bare metal on the same panel that is being welded as close as possible to the weld point to complete the electrical cir cuit for the welder and enable the current to flow BI Apprentice w
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