Determine the Extent of Damage to Aluminum Body Panels; Repair Or Replace

Determine the extent of damage to aluminum body panels; repair or replace. Lesson Plan for CRT 130-1 NON-STRUCTURAL ANALYSIS AND DAMAGE REPAIR SECTION I

Course HS Title: Non-Structural Analysis and Damage Repair Program: KCTCS Courses included in HS Title: (Lesson is prepared for course highlighted.) KCTCS Course No. KCTCS Course Title

Introduction/Conte This lesson will instruct the student on how to determine the extent of damage to xt aluminum body panels, and repair or replace. Knowledge of these techniques and the skills required to correct problems associated with this task are necessary for a student to acquire if they wish to compete for high paying, high skilled jobs in an Automotive Repair Facility. Entry level technicians need to be able to perform this task to 100% accuracy. Incorrectly performing this task can lead to an automobile accident or create customer satisfaction issues. Prepared By School Date:

Lesson Grade Level No. Students No.IEP's: Length:

Task Determine the extent of damage to aluminum body panels; repair or replace.

N Objective o. Given the proper tools and instruction, the student will be able to determine the extent of damage to 1 aluminum body panels, repair or replace, and pass a written test covering the task with 100% accuracy.

Connections: New Common Core: RST 11-12-2 RST 11-12-3 A-CED-4 New Common Core Technical TD-SYS-1 TD-OPS-3 New Science Standards HS-PS2-3. Skills Standards: AA001 EG011 INSTRUCTIONAL MATERIALS/TECHNOLOGY

Teacher Designed Materials and Other Handouts

Textbooks and Workbooks Editi Pag Author Title/ISBN No. Publisher on es ASE Test Prep Non-Structural Analysis and Various Third Delmar 19 Damage Repair Duffy Auto Body Repair Technology Fifth Delmar 345 Thomas/Jun Seco Goodheart Collision Repair and Refinishing 334 d nd /Wilcox

Equipment Quantity Item Source

Content/Presentation/Demonstration Outline Instruct students that the repair of aluminum panels requires much more care than the working of steel panels. Let them know that aluminum is much softer than steel, yet it is more difficult to shape once it becomes work hardened. Also, it also melts at a lower temperature and distorts readily when heated. Let students know that aluminum body and frame parts are usually 1 1/2 to 2 times as thick as steel parts. When damaged, tell them aluminum feels harder or stiffer to the touch because of work hardening. Explain that these characteristics must be taken into consideration when working with damaged aluminum panels. Tell students that some OEM manufacturers use magnesium components and special care must be taken when repairing and/or welding near these components. Let them know that Magnesium is a flammable metal and once it is ignited it is very difficult, if not impossible, to extinguish. Explain that body panels made from composite materials require specific procedures for repair to restore them to pre- accident condition. Tell them to always follow manufacturer’s recommendations for repair materials and procedures. Instruct students that understanding the differences in the methods and techniques used in manufacturing vehicles will help technicians understand some of the uniqueness of the aluminum vehicle from its steel counterparts. Let them know that that most of the exterior aluminum body parts and their reinforcing pieces are die stamped and resistance spot welded, much like those of steel. Tell students that unlike steel, however, the reparability of aluminum is very limited as it becomes work hardened and unworkable with a limited amount of flexing and bending, such as typically occurs in a collision. Explain that the loss of flexibility and the work hardening that occurs on even a minor damaged surface often makes repairing an outer body panel a questionable task. Instruct students that often, the panel must be replaced as opposed to being straightened, which results in higher repair costs. Tell them that small dents .and minor dings are normally repairable, so long as access is available from the back side. However, let students know that because aluminum does not have a “memory,” damage such as hail dents is not as easily repaired as when it occurs on steel panels. Be sure students also understand that certain areas, such as the center of a panel, are more easily repaired than the outer edges, because of the additional work hardening that occurs when they are die stamped. Tell them that what may appear to be a very repairable crease on the edge of a hood or a door, for example, may result in the metal becoming cracked before the damaged surface is smoothed out

Applications/Practice 1 Refer to content

Evaluation and feedback Prior to Testing or Lab Work Objective 1. / Formative assessment / Instructor will observe students as they practice the procedure to assure correct procedure and safety practices are being followed. A checklist will be utilized to chart 1 student progress on the task. Questioning techniques will be utilized as necessary to demonstrate student comprehension / Adaptations and/or accommodations for special needs students will be added if required.

STUDENT ASSESSMENT: (Assess student progress with performance criteria.) Objective 1 / Summative assessment / written test questions on stated objective / adaptation and / or 1 accommodations for special needs students will be added if required

IMPACT--Reflection/Analysis of Teaching and Learning: (How did students’ progress in relation to the state objectives? Was the instruction successful? Analyze samples of student work particularly that which is unsatisfactory, for the purpose of planning further instruction.)

REFINEMENT--Lesson Extension and Follow-up: (To be filled in as the lesson is modified during initial planning and/or during the teaching learning process.)