32405301Basic Sheet Metal Repair & Welding Fundamentals
Course Information
Description
Course material covers the introduction in the use of an oxyacetylene welding/cutting outfit as related to collision repairs. A heavy emphasis is placed on the mig welding process, types of welds and techniques used of hammer and dolly, pry tools, stud guns, air and electrical tools, hydraulic-porto-power jacks and other straightening tools, used in the processes of metal finishing and plastic filling.
Total Credits
5
Course Competencies
  1. Demonstrate workplace and personal safety
    Assessment Strategies
    Skill demonstration in shop
    Criteria
    Select and use proper personal safety equipment; take necessary precautions with hazardous operations and materials in accordance with federal, state, and local regulations.
    Locate OEM procedures to identify material and composition of the vehicle being repaired (mild steel, high strength steel, ultra-high strength steel, aluminum, stationary glass, etc.)
    Locate procedures and precautions that may apply to the vehicle being repaired, including materials used in the repair.
    Perform vehicle clean-up; complete quality control using a checklist on operations performed.
    Determine telematic/connectivity of the vehicle and recognize the need to place vehicle in service mode.
    Demonstrate knowledge of hazards related to high voltage systems/electric vehicles, including electrocution, fire, explosion, arc flash, gasses and fumes, hazardous chemicals, and EMF, and how to properly respond to emergency situations.

  2. Perform damage analysis on a vehicle
    Assessment Strategies
    Skill demonstration in shop
    Criteria
    Analyze damage to determine appropriate repair methods in accordance with manufacturer's recommendations and guidelines. HP-G
    Determine the direction, point(s) of impact, and extent of direct, indirect, and inertia damage. HP-G
    Gather details of the incident/accident necessary to determine the full extent of vehicle damage. HP-G
    Identify and record pre-existing damage. HP-G
    Identify and record prior repairs. HP-G
    Determine parts, components, material type(s) and procedures necessary for a proper repair. HP-I
    Identify type and condition of finish; determine refinish labor operations as required. HP-I
    Identify suspension, electrical, and mechanical component physical damage. HP-G
    Identify safety systems physical damage. HP-G
    Identify interior component damage. HP-G
    Identify add-on accessories and modifications. HP-G
    Perform a prescan; identify and document illuminated dash malfunction indicator lamp(s) (MIL) and stored diagnostic codes. HP-I

  3. Prepare vehicle surfaces
    Assessment Strategies
    Skill demonstration in shop
    Criteria
    Inspect, remove, store, protect, and replace exterior trim and components necessary for proper surface preparation. HP-I
    Soap and water wash entire vehicle; use appropriate cleaner to remove contaminants. HP-I
    Soap and water wash entire vehicle; complete pre-repair inspection checklist. HP-I
    Prepare damaged area using water-based and solvent-based cleaners. HP-I
    Remove corrosion protection, undercoating, sealers, and other protective coatings as necessary to perform repairs. HP-I
    Inspect, remove, and reinstall repairable plastics and other components for off-vehicle repair. HP-I

  4. Perform metal finishing and body filling
    Assessment Strategies
    Skill demonstration in shop
    Criteria
    Locate and repair surface irregularities and straighten contours on a damaged body panel using power tools, hand tools, and weld-on pulling attachments. HP-I
    Demonstrate hammer and dolly techniques. HP-I
    Heat shrink stretched panel areas to proper contour. HP-G
    Cold shrink stretched panel areas to proper contour. HP-I
    Identify body filler defects; correct the cause and condition. (Pinholing, ghosting, staining, over catalyzing, etc.) HP-I
    Identify different types of body fillers. HP-G
    Shape body filler to contour; finish sand. HP-I
    Mix and apply body filler. HP-I

  5. Perform metal welding, cutting, and joining
    Assessment Strategies
    Skill demonstration in shop
    Criteria
    Determine the correct GMAW welder type, electrode/wire type, diameter, and gas to be used in a specific welding situation. HP-I
    Set up, attach work clamp (ground), and adjust the GMAW welder to "tune" for proper electrode stickout, voltage, polarity, flow rate, and wire-feed speed required for the substrate being welded. HP-I
    Store, handle, and install high-pressure gas cylinders; test for leaks. HP-I
    Determine the proper angle of the gun to the joint and direction of gun travel for the type of weld being made. HP-I
    Protect adjacent panels, glass, vehicle interior, etc. to prevent damage from welding and cutting operations. HP-G
    Identify hazards; foam coatings and flammable materials prior to welding/cutting procedures. HP-G
    Protect computers and other electronics/wires prior to welding procedures. HP-G
    Clean and prepare the metal to be welded, assure good metal fit-up, apply weld-through primer if necessary, and clamp or tack as required. HP-I
    Determine the joint type (butt weld with backing, lap, etc.) for weld being made. HP-I
    Determine the type of weld (continuous, stitch weld, plug, etc.) for each specific welding operation. HP-I
    Perform the following welds: plug, butt weld with and without backing, and fillet etc., in the flat, horizontal, vertical, and overhead positions. HP-I
    Perform visual evaluation and destructive test on each weld type. HP-I
    Identify the causes of various welding defects; make necessary adjustments. HP-I
    Identify cause of contact tip burn-back and failure of wire to feed; make necessary adjustments. HP-G
    Identify cutting process for different substrates and locations; perform cutting operation. HP-I
    Perform rivet bonding procedures. HP-I
    Dress/grind weld as needed.