JEFFERSON COLLEGE COURSE SYLLABUS AUT 125. Auto Collision: Non-Structural Repair II. 3 Credit Hours. Prepared by: Howard Hesketh

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1 JEFFERSON COLLEGE COURSE SYLLABUS AUT 125 Auto Collision: Non-Structural Repair II 3 Credit Hours Prepared by: Howard Hesketh Career & Technical Education Brenda C. Russell, Associate Dean

2 AUT 125 Auto Collision: Non-Structural Repair II I. CATALOGUE DESCRIPTION A. prerequisite and or corequisite Auto Collision: Non-Structural Repair I B. credit hour award 3 credit hours C. Description Students will learn to remove and replace bolted and welded panels. Removal of welded panels will utilize metal cutting techniques using both oxyacetylene and plasma equipment. Students learn the auto body MIG welding process, the kinds of welds required, and the welding techniques necessary to repair vehicles to industry standards. Upon successful completion of this course students will be prepared to pass the I-CAR welding test. II. COURSE GENERAL OBJECTIVES A. Steel GMA (MIG) Welding B. Weld & Cut Steel - Oxyacetylene C. Weld & Cut Steel - Spot Welding D. Structural Parts Steel Panels & Pillars E. Structural Parts Steel Assemblies & Rails F. Structural Parts Steel Assembly & Frame G. Adhesive Bonding H. Automotive Foams I. Panel Replacement Aluminum III. COURSE OUTLINE (COURSE CONTENT WILL BE DRAWN FROM THIS) I. Steel GMA (MIG) Welding A. Principles and Setup 1. Identify the different parts of a GMA (MIG) welder and general maintenance requirements of each part. 2. Identify GMA (MIG) welding heat-management techniques. 3. Identify the types of shielding gas recommended for GMA (MIG) welding. 4. Identify the different of electrode wire and deciphering the American Welding Society (AWS) code for each type of wire. 5. Prepare the surface of a substrate for welding. 6. Know the variables which may affect weld quality. 7. Determine the best welding technique for the joint being made. 8. Identify weld defects for a variety of types of joints and list what causes the defects.

3 B. GMA (MIG) Plug Weld 1. Describe how a plug weld is made. 2. Inspect a plug weld for visual defects using the I-CAR GMA (MIG) welding gauge. 3. Destructive test a plug weld. 4. List the steps required to make a plug weld on a vehicle. C. GMA (MIG) Fillet Weld 1. Describe how a fillet weld is made. 2. Inspect a fillet weld for visual defects using the I-CAR GMA (MIG) welding gauge. 3. Destructive test a fillet weld. 4. List the steps required to make a fillet weld on a vehicle. D. GMA (MIG) Butt Joint With Backing Weld 1. Describe how a butt joint with backing weld is made. 2. Inspect a butt joint with backing weld for visual defects using the I-CAR GMA (MIG) welding gauge. 3. Destructive testing a butt joint with backing weld. 4. List the steps required to make a butt joint with backing weld on a vehicle. E. GMA (MIG) Open Butt Joint Weld 1. Describe how an open butt joint weld is made. 2. Inspect an open butt joint weld for visual defects using the I-CAR GMA (MIG) welding gauge. 3. Destructive test and open butt joint weld. 4. List the steps required to make an open butt joint weld on a vehicle. II. Welding and Cutting Steel - Oxyacetylene Welding & Cutting & Plasma Arc Cutting A. Oxyacetylene Process 1. Define applications for the oxyacetylene process. 2. List the safety protection required when using oxyacetylene equipment. 3. Define the equipment requirements for the oxyacetylene process. 4. Set up oxyacetylene equipment and check for leaks. 5. Adjust for a neutral; carburizing and oxidizing flame. B. Brazing 1. Explain how the brazing process works. 2. Determine the equipment and materials required for brazing. 3. Define the process variables for brazing. 4. Practice the brazing procedure.

4 C. Oxyacetylene Welding 1. Define applications for oxyacetylene welding. 2. Define oxyacetylene welding process variables. 3. Make oxyacetylene welded joints. 4. Inspect oxyacetylene welded joints. D. Heating And Cutting 1. Understand procedures, applications, and equipment for oxyacetylene heating. 2. Practicing heating sheet steel with oxyacetylene equipment. 3. Understand procedures, applications, and equipment for oxyacetylene cutting. 4. Practice cutting sheet steel with oxyacetylene equipment. 5. Understand procedures, applications, and equipment for plasma arc cutting. 6. Practice cutting sheet steel with a plasma arc cutter. III. Welding and Cutting Steel - Spot Welding A. Squeeze-Type Resistance Spot Welding (STRSW) Process 1. Define the STRSW process. 2. Identify STRSW parts and their function. 3. Determine where and when STRSW can be used. 4. Explain welder setup B. Making the Resistance Spot Weld 1. Prepare a panel for resistance spot welds. 2. Fit-up a panel and align the welder. 3. Use shunting. 4. Visually inspect and destructively test resistance spot welds. 5. Know OEM recommendations for spot welds. C. Weld Bonding 1. Describe the weld-bonding process. 2. Determine where weld-bonding can be used. 3. Make successful weld bonds. 4. Test weld-bonded panels. 5. Choose a resistance spot welder. IV. Structural Parts Steel Panels & Pillars A. Rocker Panels and Pillars 1. Identify part locations, definitions, and construction. 2. Remove and install foam filler. 3. Restore corrosion protection when using foam filler. 4. Explaining the criteria for repair or replace decisions. 6. Identify repair options and procedure locations. 7. Explain general sectioning guidelines. 8. Locate reinforcements. 9. Identify types of sectioning joints and joint considerations. 10. Restoring vehicle dimensions and integrity.

5 B. Rocker Panels 1. Identify rocker panel designs. 2. Identify specific rocker panel repair considerations. 3. Explain how to repair a rocker panel, including inner, outer and reinforcement removal, replacement preparation, and installation procedures. C. A-Pillars 1. Identify A-pillar designs. 2. Identify specific A-pillar repair considerations. 3. Explain hot to repair an A-pillar, including inner, outer, and reinforcement removal, replacement preparation, and installation. D. B-Pillars 1. Identify B-pillar designs. 2. Identify specific B-pillar repair considerations. 3. Make and use cutting jigs when sectioning. 4. Explain how to repair a B-pillar, including inner, outer, and reinforcement removal, replacement preparation, and installation. E. C-Pillars and D-Pillars 1. Identify C-pillar designs. 2. Identify D-pillar designs. 3. Identify specific C-pillar repair considerations. 4. Identify specific D-pillar repair considerations. F. Uniside Considerations 1. Explain uniside construction 2. Identify the types of uniside door opening assemblies. 3. Explain uniside replacement considerations. 4. Explain roof removal considerations. G. Full Rear Body Sectioning 1. Know sectioning procedures for the full rear body with and without the roof. 2. Explain recycled assembly requirements. 3. Determine sectioning locations. 4. Explain full disclosure and liability. 5. Explain the advantages and disadvantages of full rear body sectioning. V. Structural Parts Steel Assemblies & Rails A. Working with Structural Parts 1. Identify structural parts. 2. Know procedure for replacing structural parts at factor seams and sectioning structural parts. 3. Make attaching inserts. 4. Identify and make different sectioning joints. B. Radiator Core Supports

6 1. Identify the different designs of radiator core supports. 2. Explain radiator core support repair options and considerations. C. Apron Assemblies 1. Identify the different apron assembly designs. 2. Explain apron assembly repair options and considerations. D. Front Rails 1. Identify the different rail designs. 2. Identify crush zones and extra-strength areas and the reason for these design characteristics. 3. Explain rail repair options and considerations. E. Using Recycled Parts and Assemblies 1. Explain why recycled parts are used. 2. Explain the issues involving the use of recycled parts. 3. Determine the condition of recycled parts. 4. Prepare recycled parts. 5. Install recycled parts. F. Floor Pans And Trunk Floors 1. Identify designs of the floor pan and trunk floor. 2. Explain floor pan trunk floor repair options and considerations. G. Rear Rails 1. Identify designs of rear rails. 2. Explain rear rail repair options and considerations. VI. Structural Parts Steel Assembly & Frame A. Body-Over-Frame Designs 1. Know body-over-frame (BOF) identification. 2. Know body-over-frame construction. B. Frame Repair 1. Perform BOF damage analysis. 2. Know welding equipment requirements for full frames. 3. Know the procedure for a full-frame crack repair. C. Frame Sectioning 1. Know general sectioning guidelines. 2. Know vehicle-maker-specific full-frame sectioning procedures. 3. Know Tech-Cor procedure for full-frame sectioning. D. Frame Attachments 1. Know bracket replacement. 2. Know rivet replacement. 3. Know body mount replacement. 4. Explain full-frame accessory considerations.

7 E. Vehicle Body Assembly 1. Perform vehicle body structural part identification. 2. Know vehicle body sectioning procedures. VII. Adhesive Bonding A. Adhesive Bonding Materials 1. Identify some vehicle makers that use adhesives. 2. Describe the difference between epoxy, acrylic, and urethane materials. 3. Describe the considerations for working with adhesives. B. Attachment Processes 1. Describe different types of weld bonding. 2. Describe the types of rivets used for rivet bonding. 3. Explain special considerations for using adhesives for aluminum repair. C. Two-Part Adhesive Bonding Repairs 1. Explain the considerations for separating panels. 2. Describe when primers may be required. 3. Prepare parts for adhesive bonding. 4. Describe how attached parts should be moved once attached. D. One-Part Adhesive Bonding Repairs 1. Describe methods for removing parts that are attached using one-part adhesive. 2. Explain the processes for preparing a one part adhesive bed. 3. Describe the processes for preparing a replacement part for one-part urethane. VIII. Automotive Foams A. Overview Of Automotive Foams 1. Explain why foam is used on vehicles. 2. Identify where foam may be located. 3. Identify the different types of foam used in vehicles. 4. Explain the uses of each type of foam. B. Automotive Replacement Foam Types 1. Identify the differences between various foam types available for collision repairs. 2. Describe the uses for sound dampening material. 3. Explain the difference between flexible and rigid foam. 4. Explain where structural foam may be used. 5. Explain the function of structural foam.

8 C. Foam Safety And Repair 1. Identify the proper safety equipment that should be worn when working with foam. 2. Explain safety considerations when working around foam with heat. 3. Identify foam that is installed by the vehicle maker. 4. Make foam samples for comparison. 5. Compare vehicle maker foam to replacement foam samples. D. Preparing Parts For Foam 1. Explain tools and techniques used to remove foam. 2. Prepare a new part for foam installation. 3. Prepare parts with existing foam for new foam installation. 4. Reattach foam that is being reused. 5. Explain which materials can be sued for making dams. 6. Explain expansion rate variables for foam. IX. Panel Replacement Aluminum A. Aluminum 1. Develop a repair plan for aluminum part replacement. 2. Define galvanic corrosion. 3. Understand how to reduce the risk of galvanic corrosion. B. Replacing Bolted And Adhesively bonded Parts 1. Identify vehicle maker attachment methods versus repair attachment methods. 2. Replace bolt-on aluminum exterior parts. 3. Determine when to discard coated fasteners. 4. Replace adhesively bonded panels. 5. Identify bolt-on part design characteristics. 6. Inspect for proper panel alignment. C. Replacing Riveted and Rivet-Bonded Panels 1. Identify riveted aluminum exterior panels. 2. Identify rivet installation and removal tools. 3. Remove and replace a riveted panel. D. Replacing Hemmed And Clinched Panels 1. Identify hemmed aluminum exterior panels. 2. Identify clenched aluminum exterior panels. E. Replacing Welded Panels 1. Identify welded aluminum exterior panels. 2. Understand the process of removing welded panels. 3. Replace a welded panel with welding 4. Finish the repair.

9 II. METHOD(S) OF INSTRUCTION A. Class lecture B. Demonstration C. Lab experience III. REQUIRED TEXTBOOK(S) (WITH PUBLICATION INFORMATION) I-CAR material provided by instructor. IV. REQUIRED MATERIALS (STUDENT) Safety glasses Dust masks Gloves Face shield Note paper and pen/pencil V. SUPPLEMENTAL REFERENCES To be determined VI. METHOD OF EVALUATION (STUDENT OUTCOMES ASSESSMENT) A. Written exams B. Class assignments C. Lab assignments D. Class participation VII. ADA AA STATEMENT Any student requiring special accommodations should inform the instructor and the Coordinator of Disability Support Services (Library; phone , ext. 3169). VIII. ACADEMIC HONESTY STATEMENT All students are responsible for complying with campus policies as stated in the Student Handbook (see College website id=84).

10 IX. ATTENDANCE STATEMENT Students earn their financial aid by regularly attending and actively participating in their coursework. If a student does not actively participate, he/she may have to return financial aid funds. Consult the College Catalog or a Student Financial Services representative for more details. Student s grade will also be based on participation in class and attendance.