1st Year Apprenticeship1st Year Apprenticeship
Metal WorkMetal WorkIn this block you will learn
about:• Metals and their properties• Deformation effects after impact• Tools used for effective repair• Stretching and shrinking• Paintless dent removal
Body SteelsBody Steels• Hot rolled
– thickness ranges 2-8 mm
– generally used for full frames, sub frames (unibody) and crossmembers
• Cold rolled– hot rolled, acid
rinsed, cold rolled thin, then annealed
– better surface quality
– good workability– most unibody panels
are cold rolled steel– stamping process
increases strength
Cold Rolling Mill to Cold Rolling Mill to StampingsStampings
Grain Structures of SteelGrain Structures of Steel
HSLAHSLA
Mild SteelMild Steel
Properties of SteelProperties of Steel
• Mild Steel • HSS • HSLA• UHSS• AHSS
up to 30,000 psi yield strength30 - 70,000 psi yield strength
75 - 100,000 psi yield strength100- 160,000 psi yield strength110 – 180,000 psi yield strength
HSSHSS• Gets its initial strength
during the heating/cooling treatment from the steel manufacturer
• Is used mainly for load bearing components in the body structure, however more commonplace today throughout entire body structure
• May be repaired cold or with controlled heat
• More difficult to repair than mild steel
• Yield strength of up to 70,000 psi.
• Lack of available identification for HSS means treat all steel as HSS!
HSLAHSLA• Like HSS except
varying alloying elements (chemicals) are added during the manufacturing process to increase its strength (yield and tensile)
• May be reworked cold or with controlled heat application
• Found in areas such as:– Door intrusion beams– Bumper
reinforcements– Lock pillars– Front and rear frame
rails– Hinge pillars (A,B,C)
• Yield strength up to 110,000 psi.
UHSS/AHSSUHSS/AHSS• The strongest of the
structural steels found in today's automobiles
• Often referred to as Boron, Martensitic, Dual phase steels
• Found in these areas:– Front and rear bumper
reinforcements– intrusion beams– A,B,C pillars (some
vehicles)
• No heat No heat whatsoever is to be whatsoever is to be applied to any applied to any component of this component of this designation!designation!
• These steels are generally not repairable
• Require special considerations when removing/sectioning
Identification of SteelsIdentification of Steels• Location and application of HSS steels vary
widely from manufacturer to manufacturer• Sources of information include:
– OEM body repair manuals– Internet sources (OEM approved)– Mitchell manuals (estimating manuals)
• If you cannot positively identify the If you cannot positively identify the makeup of a component, you must treat it makeup of a component, you must treat it as HSS!as HSS!
HSS Locations
Part LoadingPart Loading• Tension:
• a load that tries to pull parts straight apart• Compression
• a load that forces parts straight into one another• Shear
• A load that pulls sideways• Cleavage
• a load that pulls parts away from each other at an angle
• Peel• a load that pulls parts straight away from one another
Loads present during a Loads present during a collisioncollision
TerminologyTerminology• Yield strength:
– The minimum amount of force any piece of metal can resist without bending or deforming permanently
• Yield Point: – The amount of force that a piece of metal can resist without tearing or breaking
• Tensile strength– is measured as the maximum force per unit of
area that causes a complete fracture of break
TerminologyTerminology• Work Hardening
– Is the upper limit of plastic deformation, causing the metal to become hard in the bent area
• Malleability– is the property which allows deformation under
compression or upsetting (shrinking)• Elasticity
– is the ability of the metal to be bent or stretched and spring back to its original shape
TerminologyTerminology• Plasticity:
– The property that permits metal to change shape when sufficient force is applied to it
• Plastic Deformation: – The ability of the metal to be bent or formed
into different shapes ( bent beyond its elastic limit)
• Elastic Deformation: – The ability of the metal to be stretched or
bent and return to its original state
TerminologyTerminology• Torsional strength
• is the property of a material to withstand a twisting force
• Shear Strength• is a measure of how well a material can
withstand forces acting to cut or slice it apart
• Compressive Strength• is the property of a material to withstand
being crushed
Metal Strength Metal Strength TerminologyTerminology
Elastic DeformationPlastic Deformation
TerminologyTerminology• Rigidity:
– Opposite of plasticity. • example: Cast iron will not bend or deform, it will
only break under load
• Ductility:– ability of a metal to plastically deform
without breaking or fracturing, with the cohesion between the molecules remaining sufficient to hold them together
Heat and Sheet MetalHeat and Sheet Metal• The point at which Steel melts is 2600
Degrees F
• We should know the effects of the temperature change between 400 - 1600 degrees F.
• Three Effects:• scaling• changes in grain structure• expansion and contraction
Temperature and Colour Change
• Light film of scale (iron oxide) 430 FLight film of scale (iron oxide) 430 F
• Pale yellowPale yellow / / Straw Straw / / BrownBrown / / PurplePurple / / Light BlueLight Blue
• Dark Blue / 600 degrees FDark Blue / 600 degrees F
• Reddish Glow / 900 degrees F Reddish Glow / 900 degrees F
• Blood Red / Dark Cherry 1200 FBlood Red / Dark Cherry 1200 F
• Cherry Red 1550 degrees FCherry Red 1550 degrees F
• Critical Point 1600 degrees FCritical Point 1600 degrees F
Low Crown
High Crown
Reverse Crown
BucklesBuckles• Buckles occur when metal has been bent
past it’s elastic limit• Work hardening has occurred and a new
shape is formed• The buckles found in indirect damage are
as follows:– simple hinge– collapsed hinge– simple rolled– collapsed rolled
Direct and Indirect Direct and Indirect DamageDamage
Impact effect on a High Crown
Effect of damage on a Low Crown PanelEffect of damage on a Low Crown Panel
Effect of impact on a combination High / LowEffect of impact on a combination High / LowCrowned PanelCrowned Panel
Tension can only be removed by “unlocking” thepressure areas
Combination of BucklesCombination of Buckles
simple hinge buckle
two types of rolled buckles
Collapsed hinge buckle
Steps in Unlocking Steps in Unlocking DamageDamage
First in last outFirst in last out
“Collapsed Roll Buckle”
What happens to the Steel upon impact?
In this case, the damage (Hinged Buckle) hascaused severe damage to the molecular structure
Hammering helps the atoms to ‘vibrate’ backinto shape, or order
ToolsTools• Hammers• Dollies• Spoons• Dent pullers• Body picks• Oxy-Acetylene • Body files
Body HammersBody Hammers
Hammers
Holding the BodyHammer
DolliesDollies
Holding the Dolly
Using the Corner of the Dolly
Using the Edge of the Dolly
Using the Dolly asa tool for bumping
SpoonsSpoons
Uses of the Body SpoonUses of the Body Spoon
• Can be used as adolly in hard to reachareas
• When used withdue care, can be used for leverage
• Great tool for dispersing the force of a hammer blow
Body Picks
Body Puller Set(Slide Hammer)
Pull Rods
Other Body Working ToolsOther Body Working Tools• Pry Bars• Suction Cups• Stud Welders• Porta-spot Dent Pullers• Body Files• Slap Files• Hydraulic Porta-Power
Dent Removal ToolsDent Removal Tools
Dent Removal Dent Removal SystemsSystems
Hammer MaintenanceHammer Maintenance
Depending on thecondition of yourhammer, severalsteps may need tobe taken to restorethe ‘mirror’ finishto the surface on the face of the hammer.
From filing towet sanding andpolishing.
Locating DamageLocating Damage• Visually
• Physically
• Mechanically
Use your senseof sight and thereflection of a light source as ameans of damageidentification
If a visual referenceis not possible, feelingfor damage will bemore than satisfactory
Mechanical Methods
Hammer and Dolly
Variables:
• Force of hammer blow
• Force of Dolly rebound
• Shape of Dolly
• Working distance
Hammer on Dolly Hammer on Dolly
Hammer off Dolly
Metal FundamentalsMetal Fundamentals
• Properties of steel• Working the metal• Heat Shrinking
Detecting an ‘Oil Can’ or stretched area
Time to Shrink! Time to Shrink!
ShrinkingShrinkingShrinking Procedure Shrinking Procedure
- Hold torchat right angleto panel
- heat metal to desireddegree
- place dollybehind areato be shrunk
- hammer areafrom centre out- quenchimmediately withwet sponge
Cold ShrinkingCold Shrinking
Using a Carbon Rod for heat shrinking
Repair PlanRepair Plan• Determine the extent of
the damage • Removal of moulding,
emblems, or sound deadening materials from behind panels
• Roughing out dents with hammer, puller, or pry bar
• Metal finishing with hammer, dolly and body file
• Panel shrinking • Removal of small dents
and bulges • Filling with body filler • Filing, sanding, and
priming the fill area • Rustproofing the back
side of panels• Completion of repairs
End of Metal Repair FundamentalsEnd of Metal Repair Fundamentals