Sub-Field: Motor Industry

21098 18-May-18 1 of 6

VEHICLE BODYWORK Describe aluminium alloy vehicle body and structural components, and determine repair requirements

level: 5 credit: 4 planned review date: December 2008 sub-field: Motor Industry purpose: People credited with this unit standard are able to demonstrate knowledge of: aluminium and vehicle aluminium alloy components, the procedures to repair structural damage on an aluminium alloy vehicle body, and welding aluminium alloy vehicle body components. entry information: Open. accreditation option: Evaluation of documentation and visit by NZQA and industry. moderation option: A centrally established and directed national moderation system has been set up by the NZ Motor Industry Training Organisation. special notes: 1 The following legislation and other sources must be consulted and followed where applicable: Consumer Guarantees Act 1993; Fair Trading Act 1986; Health and Safety in Employment Act 1992; Ozone Layer Protection Act 1996; Land Transport Rule: Vehicle Repair 1998, Rule 34001 available online at http://www.landtransport.govt.nz; Transport (Vehicle Standards) Regulations 1990.

2 When the performance criteria state company policy, it is assumed that it is to the same standard as the product and vehicle manufacturers' standards.

Ó New Zealand Qualifications Authority 2018 21098 18-May-18 2 of 6

Elements and Performance Criteria element 1

Demonstrate knowledge of aluminium and vehicle aluminium alloy components. performance criteria

1.1 The characteristics of aluminium are described according to textbook descriptions.

Range: may include but is not limited to – effects of heat, hammering, hardness, weight, galvanic corrosion, corrosion resistance, recycling, absorbing impact.

1.2 Vehicle body and structural aluminium alloys, their properties, and reasons for use are described according to the vehicle manufacturers’ specifications.

Range: may include but is not limited to – aluminium copper, aluminium magnesium, aluminium magnesium silicon.

1.3 Structural aluminium alloy panels on a vehicle are identified according to the vehicle manufacturers’ specifications.

1.4Non-structural aluminium alloy panels on a vehicle are identified according to the vehicle manufacturers’ specifications.

1.5The effect of damage to aluminium alloy panels is explained according to the manufacturers’ specifications.

Range: structural, non-structural panels; tears, cracks, bends, broken rivets, damage welds.

element 2

Demonstrate knowledge of the procedures to repair structural damage on an aluminium alloy vehicle body. performance criteria

2.1 Details for a repair plan are determined according to the manufacturers’ repair specifications.

Range: may include but is not limited to – sequence of parts removal and installation, heating recommendations for adhesively bonded panel removal, cleaning and inspection, comparison of vehicle manufacturer’s installation methods compared to replacement procedures, parts and fasteners to be ordered, tools required, any special refinish and sealer operations.

2.2 Aluminium components on a vehicle that affect the repair procedures are identified according to the manufacturers’ repair specifications.

Range: includes but is not limited to – door intrusion beams, framing, hinges, bumper reinforcements, trim components.

2.3 Methods of identifying structural damage on a vehicle are explained according to the manufacturers’ repair specifications.

Range: includes but is not limited to – visual, measuring, primary damage, secondary damage.

2.4 Precautions to take when fitting non-ferrous metal panels to ferrous metal panels are explained in terms of corrosion and/or electrolytic effects.

Range: includes but is not limited to – using non-conductive materials, protective coatings, coated fasteners, plastic and/or rubber washers.

2.5 Procedures for identifying cracks in aluminium panels are described according to the manufacturers’ repair specifications.

Range: visual, dye penetrant.

2.6 Procedures for attaching aluminium panels on a vehicle are described according to the manufacturers’ repair specifications.

Range: rivets (solid, blind, self-piercing), adhesives, welding, hemming, clinching.

2.7 Procedures for aligning structural aluminium panels are described according to the manufacturers’ repair specifications.

Range: includes but is not limited to – alignment machine, measuring, heat assistance, pull angles, anchor points.

2.8 Procedures for removing damaged panels are described according to the manufacturers’ repair specifications.

Range: includes but is not limited to – removing welds, removing rivets, removing adhesives.

2.9 Procedures for replacing damaged panels are described according to the manufacturers’ repair specifications.

Range: includes but is not limited to – preparation, adhesives, rivets, welding, protection against galvanic corrosion.

2.10 Procedures for repairing damaged structural aluminium panels are described according to the manufacturers’ repair specifications.

Range: sectioning, straightening, adhering to regulations.

2.11 Procedures to apply anti-vibration materials to an aluminium body are described according to the manufacturers’ repair specifications.

Range: includes but is not limited to – adhesives, foam, anti-flutter materials, anti-corrosion fluids.

2.12 The use of dedicated equipment when repairing aluminium panels is determined according to the manufacturers’ repair specifications. element 3

Demonstrate knowledge of welding aluminium alloy vehicle body components. performance criteria

3.1 Safe working procedures when welding and working with aluminium are explained according to the vehicle and material manufacturer’s specifications and legislation requirements.

Range: personal safety, safety of other people, workshop safety, environmental safety, welding equipment safety, vehicle component safety (computers and sensitive parts).

3.2 Use of weld removal, preparation, and welding equipment for welding aluminium panels is explained according to the manufacturers’ repair specifications.

Range: includes but is not limited to – gas metal arc (MIG) welding, grinder, cutter.

3.3 Procedures for welding aluminium are described according to the manufacturers’ repair specifications.

Range: includes but is not limited to – set up of welder, use of argon shielding gas, specified filler wire for make and model vehicles, metal preparation, using push technique, dressing welds.

3.4 Procedures for replacing spot welds on aluminium panels are described according to the manufacturers’ repair specifications.

Range: rivet and/or bonding, plug weld.

Comments on this unit standard

Please contact the NZ Motor Industry Training Organisation [email protected] if you wish to suggest changes to the content of this unit standard.

Please Note Providers must be accredited by the Qualifications Authority or a delegated inter- institutional body before they can register credits from assessment against unit standards or deliver courses of study leading to that assessment.

Industry Training Organisations must be accredited by the Qualifications Authority before they can register credits from assessment against unit standards.

Accredited providers and Industry Training Organisations assessing against unit standards must engage with the moderation system that applies to those standards.

Accreditation requirements and an outline of the moderation system that applies to this standard are outlined in the Accreditation and Moderation Action Plan (AMAP). The AMAP also includes useful information about special requirements for providers wishing to develop education and training programmes, such as minimum qualifications for tutors and assessors, and special resource requirements.

This unit standard is covered by AMAP 0014 which can be accessed at http://www.nzqa.govt.nz/site/framework/search.html.

Ó New Zealand Qualifications Authority 2018