Identify different methods of attaching non-structural components (squeeze type resistant spot welds (STRSW), riveting, non-structural adhesive, silicon bronze, etc.)

Lesson Plan for

CRT 130-3

NON-STRUCTURAL ANALYSIS AND DAMAGE REPAIR SECTION III

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/Context / This lesson will instruct the student on how to identify different methods of attaching non-structural components (squeeze type resistant spot welds (STRSW), riveting, non-structural adhesive, silicon bronze, etc.). 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 a Collision 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:
Grade Level / No. Students / No.IEP's: / Lesson Length:
Task
Identify different methods of attaching non-structural components (squeeze type resistant spot welds (STRSW), riveting, non-structural adhesive, silicon bronze, etc.)
No. / Objective
1 / Given the proper tools and instruction, the student will be able to identify different methods of attaching non-structural components (squeeze type resistant spot welds (STRSW), riveting, non-structural adhesive, silicon bronze, etc.), and pass a written test covering the task with 100% accuracy.

Connections:

New Common Core:
RST 11-12-2
RST 11-12-3
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

Author / Title/ISBN No. / Edition / Publisher / Pages
Duffy / Collision Repair Fundamentals / 2008 / Delmar / 107
Thomas/Jund / Collision Repair and Refinishing / Second / Delmar / 137


Equipment

Quantity / Item / Source
As Needed / Rivet Gun/Welder / As Needed


Content/Presentation/Demonstration Outline

Instruct students that squeeze-type resistance spot welding uses electric current through the base metal to form a small, round weld between the base metals. Let them know that it is the only accepted form of pressure welding for collision repair. Resistance spot welding focuses the heat onto a small area. Tell students that a series of pressure spot welds are sometimes used to secure replacement panels onto the body structure of wrecked cars or trucks.
Tell students that hybrid bonding refers to using more than one method to join structural body parts on a vehicle. Let them know that hybrid bonding is now being used during the manufacture of today’s steel and aluminum unibody structures.
Instruct students that Weld bonding uses adhesive and resistance spot welds to join steel or aluminum body panels together during vehicle manufacture. Explain that when on the vehicle assembly line, a weld- through structural adhesive is applied to the body flanges. Then spot welds are also used to fuse the body panels together.
Let students know that a few manufacturers are using friction stir welds to assemble their vehicles. The panel flanges are clamped together and a small spinning wheel is forced against the panel. The friction from the spinning wheel generates enough heat to weld the panels together.
Instruct students that Rivet bonding uses adhesive and self- piercing metal rivets to join body panels on some aluminum unibody vehicles. Explain that at the factory, an epoxy adhesive is applied to flanges of the body panels. Then aluminum rivets are shot through the body panel flanges to join the aluminum panels together securely. Tell them the rivets pierce the top panel but expand and embed in the lower panel to join them.
Tell students that as the use of ultra-high-strength steel became more prevalent in the manufacturing of vehicles, new methods of bonding were introduced into the manufacturing world, Though on the manufactured vehicle it may look like old style gas brazing, the bronze was applied with a new method of silicon bronze welding, or MIG brazing.
Inform students that using wire such as CuSi³ or CuAI9 when welding advanced high-strength steel works well with pure argon as the shielding gas. The gun liner will need to be Teflon- lined to ease the passing of the copper wire. Explain that MIG brazing heat is much lower than the temperatures at which high- strength steel must be melted for GMAW. The temperatures that are too hot will cause the molecules of the steel to become brittle and make the steel susceptible to rust, so manufacturers have started to MIG braze them together.
Let students know that though this new type of MIG brazing has been used for some time in manufacturing, repair technicians should only use this method if the repair process is recommended by the manufacturer (and if the technician has the necessary equipment).


Applications/Practice

1 / Refer to content


Evaluation and feedback Prior to Testing or Lab Work

1 / 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 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.)

1 / Objective 1 / Summative assessment / written test questions on stated objective / adaptation and / or 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.)