1st Year Apprenticeship

Metal Work
In this block you will learn about:
Metals and their properties
Deformation effects after impact
Tools used for effective repair
Stretching and shrinking
Paintless dent removal

Body Steels
Hot rolled
thickness ranges 2-8
mm
generally used for
full frames, sub
frames (unibody)
and crossmembers
Cold rolled
hot rolled, acid
rinsed, cold rolled
thin, then annealed
better surface quality
good workability
most unibody panels
are cold rolled steel
stamping process
increases strength



Cold Rolling Mill to Stampings
Grain Structures of Steel
HSLA
Mild Steel
Properties of Steel
Mild Steel
HSS
HSLA
UHSS
AHSS
up to 30,000 psi yield strength
30 - 70,000 psi yield strength
75 - 100,000 psi yield strength
100- 160,000 psi yield strength
110 180,000 psi yield strength
HSS
Gets its initial strength
during the
heating/cooling
treatment from the
steel manufacturer
Is used mainly for load
bearing components in
the body structure,
however more
commonplace today
throughout entire body
structure


May be repaired cold or
with controlled heat
More difficult to repair
than mild steel
Yield strength of up to
70,000 psi.
Lack of available
identification for HSS
means treat all steel as
HSS!

HSLA
Like HSS except varying
alloying elements
(chemicals) are added
during the
manufacturing process
to increase its strength
(yield and tensile)
May be reworked cold
or with controlled heat
application
Found in areas such as:
Door intrusion beams
Bumper reinforcements
Lock pillars
Front and rear frame rails
Hinge pillars (A,B,C)
Yield strength up to
110,000 psi.


UHSS/AHSS
The strongest of the
structural steels found
in today's automobiles
Often referred to as
Boron, Martensitic, Dual
phase steels
Found in these areas:
Front and rear bumper
reinforcements
intrusion beams
A,B,C pillars (some
vehicles)
No heat whatsoever
is to be applied to
any component of
this designation!
These steels are
generally not repairable
Require special
considerations when
removing/sectioning
Identification of Steels
Location and application of HSS steels vary
widely from manufacturer to manufacturer
Sources of information include:
OEM body repair manuals
Internet sources (OEM approved)
Mitchell manuals (estimating manuals)
If you cannot positively identify the makeup
of a component, you must treat it as HSS!

HSS Locations
Part Loading
Tension:
a load that tries to pull parts straight apart
Compression
a load that forces parts straight into one another
Shear
A load that pulls sideways
Cleavage
a load that pulls parts away from each other at an angle
Peel
a load that pulls parts straight away from one another

Loads present during a
collision
Terminology
Yield strength:
The minimum amount of force any piece of metal
can resist without bending or deforming
permanently
Yield Point:
The amount of force that a piece of
metal can resist without tearing or breaking
Tensile strength
is measured as the maximum force per unit of
area that causes a complete fracture of break


Terminology
Work Hardening
Is the upper limit of plastic deformation, causing
the metal to become hard in the bent area
Malleability
is the property which allows deformation under
compression or upsetting (shrinking)
Elasticity
is the ability of the metal to be bent or stretched
and spring back to its original shape




Terminology
Plasticity:
The property that permits metal to change shape
when sufficient force is applied to it

Plastic Deformation:
The ability of the metal to be bent or formed into
different shapes ( bent beyond its elastic limit)

Elastic Deformation:
The ability of the metal to be stretched or bent
and return to its original state

Terminology
Torsional strength
is the property of a material to withstand a
twisting force
Shear Strength
is a measure of how well a material can
withstand forces acting to cut or slice it apart
Compressive Strength
is the property of a material to withstand being
crushed

Metal Strength Terminology
Elastic Deformation Plastic Deformation
Terminology
Rigidity:
Opposite of plasticity.
example: Cast iron will not bend or deform, it will only
break under load

Ductility:
ability of a metal to plastically deform without
breaking or fracturing, with the cohesion between
the molecules remaining sufficient to hold them
together

Heat and Sheet Metal
The point at which Steel melts is 2600
Degrees F

We should know the effects of the
temperature change between 400 - 1600
degrees F.

Three Effects:
scaling
changes in grain structure
expansion and contraction
Temperature and Colour Change

Light film of scale (iron oxide) 430 F

Pale yellow / Straw / Brown / Purple / Light Blue

Dark Blue / 600 degrees F

Reddish Glow / 900 degrees F

Blood Red / Dark Cherry 1200 F

Cherry Red 1550 degrees F

Critical Point 1600 degrees F
Low Crown
High Crown
Reverse Crown
Buckles
Buckles occur when metal has been bent past
its elastic limit
Work hardening has occurred and a new
shape is formed
The buckles found in indirect damage are as
follows:
simple hinge
collapsed hinge
simple rolled
collapsed rolled
Direct and Indirect Damage
Impact effect on a High Crown
Effect of damage on a Low Crown Panel
Effect of impact on a combination High / Low
Crowned Panel
Tension can only be removed by unlocking the
pressure areas
Combination of Buckles
simple
hinge
buckle
two types
of rolled
buckles
Collapsed hinge
buckle
Steps in Unlocking Damage
First in last out
Collapsed Roll Buckle
What happens to the Steel upon impact?
In this case, the damage (Hinged Buckle) has
caused severe damage to the molecular structure
Hammering helps the atoms to vibrate back
into shape, or order
Tools
Hammers
Dollies
Spoons
Dent pullers
Body picks
Oxy-Acetylene
Body files
Body Hammers
Hammers
Holding the Body
Hammer
Dollies
Holding the Dolly
Using the Corner of the Dolly
Using the Edge of the Dolly
Using the Dolly as
a tool for bumping

Spoons
Uses of the Body Spoon

Can be used as a
dolly in hard to reach
areas

When used with
due care, can be
used for leverage

Great tool for
dispersing the force
of a hammer blow


Body Picks
Body Puller Set
(Slide Hammer)
Pull Rods
Other Body Working Tools
Pry Bars
Suction Cups
Stud Welders
Porta-spot Dent Pullers
Body Files
Slap Files
Hydraulic Porta-Power


Dent Removal Tools
Dent Removal Systems
Hammer Maintenance
Depending on the
condition of your
hammer, several
steps may need to
be taken to restore
the mirror finish
to the surface on
the face of the
hammer.

From filing to
wet sanding and
polishing.
Locating Damage
Visually

Physically

Mechanically
Use your sense
of sight and the
reflection of a
light source as a
means of damage
identification
If a visual reference
is not possible, feeling
for damage will be
more than satisfactory
Mechanical Methods
Hammer and Dolly

Variables:

Force of hammer blow

Force of Dolly rebound

Shape of Dolly

Working distance


Hammer on Dolly
Hammer off Dolly
Metal Fundamentals
Properties of steel
Working the metal
Heat Shrinking
Detecting an Oil Can or stretched area
Time to Shrink!
Shrinking
Shrinking Procedure
- Hold torch
at right angle
to panel

- heat metal
to desired
degree

- place dolly
behind area
to be shrunk

- hammer area
from centre out
- quench
immediately with
wet sponge
Cold Shrinking
Using a Carbon Rod for heat shrinking
Repair Plan
Determine the extent of
the damage
Removal of moulding,
emblems, or sound
deadening materials
from behind panels
Roughing out dents
with hammer, puller, or
pry bar
Metal finishing with
hammer, dolly and
body file
Panel shrinking
Removal of small
dents and bulges
Filling with body filler
Filing, sanding, and
priming the fill area
Rustproofing the back
side of panels
Completion of repairs
End of Metal Repair Fundamentals