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Introduction Introduction ® SPS07-STMAN1-E INTRODUCTION Topic A. Obligations To The Customer Throughout the damage analysis and repair process, And Liability the repairer and insurer must communicate with each other and the customer. They must be in agreement with each other and the customer on how repairs will be performed. The customer must be informed of any changes in the repair plan from the original repair agreement and explain the changes and why they have to be made. The Collision Repair Industry has an obligation to correctly repair the customer’s vehicle. Collision repairs must be performed using: recommended or tested procedures from vehicle makers, I‑CAR, and other research and testing organizations. To reduce liability, make sure that all repairs are quality replacement parts and materials. performed thoroughly and correctly. Perform the repair processes and parts as written and agreed repairs as listed in the damage report and have upon in the repair order. documentation of required repairs available for customers. Be sure of the proper procedures. If items on the repair agreement are not consistent Technicians are considered the experts and are with the repair order, it can be considered fraud. expected be knowledgeable on how to perform a quality repair. Performing proper collision repairs requires using parts and procedures that keep remaining warranties Liability insurance that covers the repair facility may intact. Collision repairs must restore: not always cover all damages. For example, the policy may not cover faulty repairs, leaving liability safety. responsibility completely on the facility. A shop structural integrity. owner may find that repair facility liability coverage durability. may not cover the full amount awarded in a performance. lawsuit. The shop owner would have to pay the fit. difference. finish. © 2007–2012 Inter-Industry Conference On Auto Collision Repair 2 It is difficult to reduce the risk of liability exposure. Keeping thorough records includes more than The part that the repairer can control is the chance recording the date, mileage, and pre‑existing damage. of being found at fault. Chances can be minimized Record keeping also includes: by using recommended or tested procedures from the vehicle makers, I‑CAR, or other research and making sure all notes are legible. testing organizations. It is also important to use verifying the repairs that were made or not quality replacement parts and materials that restore made. fit, finish, durability, and perform at least as well having the customer sign a waiver for repairs as the original. Lastly, keep thorough records that that they do not want performed. Repairers document the repair process. must determine their liability on not repairing safety systems such as restraint and anti‑lock brake systems. keeping computer printouts or worksheets on file showing wheel alignment readings or vehicle dimensions before and after repairs. keeping scan tool printouts and records of computer codes for airbag, anti‑lock brake, emission, and powertrain control module (PCM) systems. attaching the OEM procedure printout to the vehicle repair order. keeping receipts for all sublet work performed. © 2007–2012 Inter-Industry Conference On Auto Collision Repair 3 Steel Unitized Structures Technologies And Repair Textbook ® IMPORTANT NOTICE This material provides general directions for collision damage repair using tested, effective procedures. Follow- ing them will help assure the reliability of the repair. I-CAR cannot accept responsibility for any individual repair, nor can it warrant to the quality of such repair. Anyone who departs from the instructions in this program must first establish that neither personal safety nor the integrity of the repair of the vehicle is compromised by the choice of methods, tools, or supplies. I-CAR does not endorse or recommend any brands or makes of vehicles, repair equipment and supplies or other products. The appearance of various makes and brand names in any I-CAR material is purely coincidental and is based on the availability of those products at the time of production. All recommendations presented in this program are based upon research programs or upon tests conducted by laboratories, manufacturers, or selected collision repair facilities. If performed as outlined, these recom- mendations will provide the basis for a thorough, professional repair. © 2007–2012 by the Inter-Industry Conference On Auto Collision Repair (I-CAR) All Rights Reserved Steel Unitized Structures Technologies And Repair v.9.4 2 © 2007–2012 Inter-Industry Conference On Auto Collision Repair CONTENTS Module 1–Steel Strength And Unitized Structures Repair ...................................................................4 A. Vehicle Features And Functions .............................................................................................................. 4 B. Steel Strength ............................................................................................................................................... 8 C. Mechanical Properties Of Steel .............................................................................................................16 D. Heat Affects On Steel ..............................................................................................................................20 E. Identifying Steel Types ..............................................................................................................................21 F. Metallurgical Designation .........................................................................................................................23 G. Review .........................................................................................................................................................32 Module 2–New Construction Processes ............................................................................................. 33 Topic A. Front Structures ..............................................................................................................................33 Topic B. Laminated Steel ..............................................................................................................................34 Topic C. Tailored Blanks ................................................................................................................................38 Topic D. Hydroformed Parts ........................................................................................................................41 Topic E. Multiple Layer Construction .........................................................................................................42 Topic F. Foams ................................................................................................................................................46 Topic G. Weld Bonding.................................................................................................................................49 Topic H. MIG Brazing ...................................................................................................................................50 Topic I. Summary ............................................................................................................................................51 Steel Unitized Structures Technologies And Repair v.9.4 3 © 2007–2012 Inter-Industry Conference On Auto Collision Repair MODULE 1–STEEL STRENGTH AND UNITIZED STRUCTURES REPAIR Topic A. Vehicle Features And Functions A-3 New unitized structures are designed to maximize occupant protec- tion during collisions. A-2 Like most new vehicles, this late model Mercedes Benz CLK sedan is loaded with safety and convenience features that add weight to the Passive safety for unitized structures includes: vehicle. n controlling collision energy forces for optimized New vehicles have many features and functions that occupant protection. This is done by designing the vehicles of just a decade or less ago did not. This the structure to optimize both collision energy includes: absorption and collision energy transfer charac- teristics. n additional electronics, including an increasing n maintaining the integrity of the passenger com- number of computers and the wiring associated partment in collisions. This is critical to limit with them. intrusion injuries to the vehicle occupants. The n increased noise, vibration, and harshness (NVH) passenger compartment is the strongest portion control. of the vehicle. n increased collision energy management. The struc- tures of late model vehicles have been designed with collision energy management and occupant protection as one of the primary goals. n additional restraints and other safety systems for increased occupant protection in collisions. All of these added features and functions add weight to the vehicle. Steel Unitized Structures Technologies And Repair v.9.4–Module 1 4 © 2007–2012 Inter-Industry Conference On Auto Collision Repair Front Rear Side Side Dodge Caliber A-4 The deformation of this front frame rail is an example of how unitized A-5 These illustrations show how collision energy is transferred through structures absorb collision energy during collisions. the structure of a vehicle during a collision. Collision energy absorption: Collision energy transfer: n is achieved through deformation of parts of the n characteristics are incorporated into the struc- structure. As a part deforms or crushes, energy is ture through
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