Metal Fabrication | Architectural Metalwork | Structural ...
metalwork
description
Transcript of metalwork
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1st Year Apprenticeship1st Year Apprenticeship
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Metal WorkMetal WorkIn 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
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Body SteelsBody 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
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Cold Rolling Mill to Cold Rolling Mill to StampingsStampings
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Grain Structures of SteelGrain Structures of Steel
HSLAHSLA
Mild SteelMild Steel
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Properties of SteelProperties of Steel
• Mild Steel • HSS • HSLA• UHSS• AHSS
up to 30,000 psi yield strength30 - 70,000 psi yield strength
75 - 100,000 psi yield strength100- 160,000 psi yield strength110 – 180,000 psi yield strength
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HSSHSS• 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!
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HSLAHSLA• 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.
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UHSS/AHSSUHSS/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 No heat whatsoever is to be whatsoever is to be applied to any applied to any component of this component of this designation!designation!
• These steels are generally not repairable
• Require special considerations when removing/sectioning
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Identification of SteelsIdentification 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 If you cannot positively identify the makeup of a component, you must treat it makeup of a component, you must treat it as HSS!as HSS!
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HSS Locations
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Part LoadingPart 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
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Loads present during a Loads present during a collisioncollision
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TerminologyTerminology• 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
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TerminologyTerminology• 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
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TerminologyTerminology• 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
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TerminologyTerminology• 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
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Metal Strength Metal Strength TerminologyTerminology
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Elastic DeformationPlastic Deformation
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TerminologyTerminology• 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
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Heat and Sheet MetalHeat 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
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Temperature and Colour Change
• Light film of scale (iron oxide) 430 FLight film of scale (iron oxide) 430 F
• Pale yellowPale yellow / / Straw Straw / / BrownBrown / / PurplePurple / / Light BlueLight Blue
• Dark Blue / 600 degrees FDark Blue / 600 degrees F
• Reddish Glow / 900 degrees F Reddish Glow / 900 degrees F
• Blood Red / Dark Cherry 1200 FBlood Red / Dark Cherry 1200 F
• Cherry Red 1550 degrees FCherry Red 1550 degrees F
• Critical Point 1600 degrees FCritical Point 1600 degrees F
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Low Crown
High Crown
Reverse Crown
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BucklesBuckles• Buckles occur when metal has been bent
past it’s 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
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Direct and Indirect Direct and Indirect DamageDamage
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Impact effect on a High Crown
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Effect of damage on a Low Crown PanelEffect of damage on a Low Crown Panel
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Effect of impact on a combination High / LowEffect of impact on a combination High / LowCrowned PanelCrowned Panel
Tension can only be removed by “unlocking” thepressure areas
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Combination of BucklesCombination of Buckles
simple hinge buckle
two types of rolled buckles
Collapsed hinge buckle
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Steps in Unlocking Steps in Unlocking DamageDamage
First in last outFirst in last out
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“Collapsed Roll Buckle”
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What happens to the Steel upon impact?
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In this case, the damage (Hinged Buckle) hascaused severe damage to the molecular structure
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Hammering helps the atoms to ‘vibrate’ backinto shape, or order
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ToolsTools• Hammers• Dollies• Spoons• Dent pullers• Body picks• Oxy-Acetylene • Body files
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Body HammersBody Hammers
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Hammers
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Holding the BodyHammer
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DolliesDollies
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Holding the Dolly
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Using the Corner of the Dolly
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Using the Edge of the Dolly
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Using the Dolly asa tool for bumping
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SpoonsSpoons
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Uses of the Body SpoonUses of the Body Spoon
• Can be used as adolly in hard to reachareas
• When used withdue care, can be used for leverage
• Great tool for dispersing the force of a hammer blow
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Body Picks
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Body Puller Set(Slide Hammer)
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Pull Rods
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Other Body Working ToolsOther Body Working Tools• Pry Bars• Suction Cups• Stud Welders• Porta-spot Dent Pullers• Body Files• Slap Files• Hydraulic Porta-Power
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Dent Removal ToolsDent Removal Tools
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Dent Removal Dent Removal SystemsSystems
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Hammer MaintenanceHammer Maintenance
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Depending on thecondition of yourhammer, severalsteps may need tobe taken to restorethe ‘mirror’ finishto the surface on the face of the hammer.
From filing towet sanding andpolishing.
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Locating DamageLocating Damage• Visually
• Physically
• Mechanically
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Use your senseof sight and thereflection of a light source as ameans of damageidentification
If a visual referenceis not possible, feelingfor damage will bemore than satisfactory
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Mechanical Methods
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Hammer and Dolly
Variables:
• Force of hammer blow
• Force of Dolly rebound
• Shape of Dolly
• Working distance
Hammer on Dolly Hammer on Dolly
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Hammer off Dolly
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Metal FundamentalsMetal Fundamentals
• Properties of steel• Working the metal• Heat Shrinking
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Detecting an ‘Oil Can’ or stretched area
Time to Shrink! Time to Shrink!
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ShrinkingShrinkingShrinking Procedure Shrinking Procedure
- Hold torchat right angleto panel
- heat metal to desireddegree
- place dollybehind areato be shrunk
- hammer areafrom centre out- quenchimmediately withwet sponge
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Cold ShrinkingCold Shrinking
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Using a Carbon Rod for heat shrinking
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Repair PlanRepair 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
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End of Metal Repair FundamentalsEnd of Metal Repair Fundamentals