(IMI ACCREDITATION - AOM133Bonding and Mechanical Fastening following Researched Repair Methods)

TECHNICIAN’S INSTRUCTIONS

Know and understand the processes and procedures involved in using researched repair methods to support the process of cutting and securing replacement body panels, using bonding and mechanical fastening techniques.

Know:

1.1. why bonding and mechanical fasteners are used in vehicle construction.

1.2. different mechanical fastenings used in vehicle construction and body

repair procedures.

Know how to:

2.1. follow researched repair methods and technical data.

2.2. follow manufacturer’s process, methods and procedures for joining panels.

2.3. work safely whilst carrying out bonding and mechanical fixing operations.

2.4. store tools and materials correctly.

2.5. prepare and protect the work area.

2.6. select and use the correct tools and equipment.

2.7. remove existing bonded and mechanically fixed panels, without causing damage to the remaining surfaces.

2.8. prepare the panel flanges ready to receive bonding and mechanical fixings.

2.9. prepare and dry fit the replacement panel section and the studded backing plate and check alignment.

2.10. locate the work-time and prepare the adhesive bonding material and application equipment.

2.11. produce an adhesive test bead

2.12. protect areas to inhibit corrosion, where required and apply adhesive in accordance with the manufacturer's specifications.

2.13. fit and align the replacement panel section, and secure using the correct clamping, bonding and mechanical fixing processes.

2.14. remove excess adhesive and achieve an acceptable cosmetic finish prior to curing.

2.15. identify if a joint is not correctly formed and take necessary action.

2.16. alert others to the curing process (notices or signs).

2.17. locate the curing times and cure the bonding material as specified in the manufacturer's recommended methods.

2.18. record information required by the assessment process.

Facilities, equipment and materials that you must check are to hand at the workstation prior to the assessment:

· personal Protective Equipment (PPE)

· materials to protect the work area

· industry approved repair methods, Material Safety Data Sheets and Product Technical Data Sheets

· industry approved steel panel section

· power sources – electric / air

· panel technicians recommended tools

· drilling and punching equipment

· drill bits and punches to suit the types of mechanical fixings

· appropriate heating and drying equipment

· infrared thermometer

· cleaning wheels

· sanding equipment

· panel chisels

· mechanical fastenings and equipment suitable for the task

· torque screwdriver / wrench

· corrosion protection materials

· suitable structural adhesive and application equipment

· cleaning and degreasing materials

· relevant industry approved repair information and methods

· mechanical fixings to include:

i. studded backing plate and plastic nuts

self-piercing rivets

ii. blind steel rivets

iii. flow-form rivets

(The above fastenings must be sized to suit the material thickness and tooling used to install them - see the repair methods for specific sizes)

Be able to use vehicle researched repair methods to support carry out cutting, of vehicle panels and securing them using bonding and mechanical fastenings:

Be able to:

3.1. identify the correct method for removing and replacing the panel section using industry approved researched repair methods.

3.2. locate and follow Material Safety Data Sheets / Material Technical Data Sheets where appropriate.

3.3. prepare and protect the work area, select correct tools and equipment.

3.4. store replacement panels in an appropriate place and protect them where necessary.

3.5. remove the existing bonded and mechanically fixed panel section without causing damage to the remaining surfaces.

3.6. prepare the panel flanges, the replacement panel and the backing plate edges to receive adhesive and mechanical fixings.

3.7. dry fit the replacement panel section and the studded backing plate to check the alignment / measurements.

3.8. locate the work-time and prepare the adhesive bonding material and application equipment.

3.9. produce an adhesive test bead.

3.10. protect areas to inhibit corrosion, where required and apply adhesive in accordance with the manufacturers specifications

3.11. fit and align the replacement panel section and studded backing plate and secure them using the correct clamping, bonding and mechanical fixing processes.

3.12. remove excess adhesive and achieve an acceptable cosmetic finish prior to curing.

3.13. identify if a joint is not correctly formed and take necessary action.

3.14. alert others to the curing process and times (notices or signs).

3.15. locate the curing times and cure the bonding material as specified in the

manufacturer's recommended methods.

3.16. use the correct tools throughout the assessment process.

3.17. clean and store tools and equipment correctly.

3.18. maintain the cleanliness and safe working conditions of the work area throughout the task.

3.19. complete final quality checks and inspections.

3.20. work safely and in accordance with current safety legislation throughout the assessment.

3.21. complete the assessment within the agreed timescale.

3.22. record information which is required by the assessment process.

3.23. complete the required knowledge assessment.

Time limit: Minimum - 2.5 Hours

Maximum - to be determined by the Assessor

TECHNICIAN JOB RECORD – PANEL BONDING AND MECHANICAL FASTENINGS

Panel or vehicle :

Registration / Ref No:

Technicians name:

Adhesive:

Batch No:

Used by date:

Primer / treatments :

Batch No:

Used by date:

Types of mechanical fixings:

Curing temperatures

Curing start time:

Curing finish time:

Test bead samples:

Assessor Name:

Signature:

Assessor No:

Date:

Assessor comments:

WORKSTATION REQUIREMENTS

AOM133 - Cutting, Bonding and Mechanical Fastenings

Equipment Specifications: The equipment must meet the minimum requirements for the material type, material thickness and all the different fastenings, which are used within the assessment test piece.

Note: Automotive materials and joining methods are constantly evolving, hence the minimum equipment specification may change as the module is revised to meet the requirements of the vehicle body repair industry.

Facilities, equipment and materials required at the workstation:

· personal Protective Equipment (PPE)

· materials to protect the work area

· industry approved repair methods, Material Safety Data Sheets and Product Technical Data Sheets

· industry approved steel panel section

· power sources – electric / air

· panel technicians recommended tools

· drilling and punching equipment

· drill bits and punches to suit the types of mechanical fixings

· appropriate heating and drying equipment

· infrared thermometer

· cleaning wheels

· sanding equipment

· panel chisels

· mechanical fastenings and equipment suitable for the task

· torque screwdriver / wrench

· corrosion protection materials

· suitable structural adhesive and application equipment

· cleaning and degreasing materials

· mechanical fixings to include:

i. studded backing plate and plastic nuts

ii. self-piercing rivets

iii. blind steel rivets

iv. flow-form rivets

(The above fastenings must be sized to suit the material thickness and tooling used to install them - see the repair methods for specific sizes)

Workstation set up required:

· Test Panel (Image 1): An industry approved steel panel section which is constructed using adhesive bonding in conjunction with self-piercing rivets with a pitch of 50mm. The flanges containing these fastenings are the ones which will be utilised during assessment.

The lower flange of the panel section is joined using spot welding.

Image 1

· Joining Methods and Equipment: Must be approved by the Assessor and suitable to complete the task to a recognised industry standard.

· Set up: The panel section must be securely set-up on a jig to allow an end section to be removed after performing one cut. The section being replaced must include a suitable bonding /adhesive and the mechanical fixings stated in the materials list.

Method:

The following new panels are required:

· a constructed steel panel section (Image 1)

· a reinforcement plate

· a repair section

Mark out and make one cut at 175mm, measured in from the right-hand side of the panel section which must incorporate a 5mm gap when the replacement panel section is fitted. The edges of the sectioned panels must be chamfered.

Image 2

Care must be taken to prevent the remaining and inner panels from becoming damaged during separation.

Note: The candidate will be referred from this task if:

i. cuts are observed through the inner strengthener or any panel flanges

ii. excessive damage to the inner strengthener is observed

(It is acceptable for the saw blade to 'touch' the inner strengthener providing it is within the criteria stated above).

Use an appropriate riveting tool kit to remove the upper self-piercing rivets.

Remove the lower self-piercing rivets using suitable methods and equipment.

Separate the panel flanges and remove the outer panel.

(Note: the flanges may be warmed using appropriate methods and equipment to facilitate

removal of the outer panel).

The candidate must allow the Assessor to inspect the inner strengthener panel before

commencing with fitting the replacement panel section. Evidence photographs must be

taken at this stage.

Remove the adhesive residue using the appropriate methods and cleaning agents.

Continue to cut the new replacement section to size.

Clamp and secure the replacement panel section in place and drill or punch 6.7mm holes into

the lower flange, including the placement of a backing plate at the joint.

Use appropriate equipment to punch four holes for the flow-form rivets at the left side of the

upper flange of the replacement panel section.

Remove the replacement panel section and deburr all the holes.

Apply adhesive to all the mating surfaces, including the backing plate, ensuring they have

sufficient corrosion protection applied.

Tighten the 3 nuts to secure the backing plate to (6NM).

Fit the replacement panel section with:

· blind rivets at the lower flange

· four flow-form rivets to the left side of the upper flange

· four SPR to the right side of the upper flange

The completed panel can be seen in image 3

Time limit: Minimum - 2.5 Hours

Maximum - to be determined by the Assessor

ASSESSMENT RESULTS SHEET

AOM133: Using Researched Repair Methods to Support the Process of Cutting Body Panels and Securing with Bonding and Mechanical Fastening

Technician’s Name:

Registration Number:

Assessor’s Name:Date: / /

Start time:

Completion time:

Critical competences. The candidate:

Achieved

3.1. identified the correct method for removing and replacing the panel section by using industry approved researched repair methods.

Comments:

3.2. located and followed the Material Safety Data Sheets / Material Technical Data Sheets where appropriate.

Comments:

3.3. prepared and protected the work area and selected the correct tools and equipment.

Comments:

3.4. stored replacement panels in an appropriate place and protected them where necessary.

Comments:

3.5. removed the existing bonded and mechanically fixed panel section without causing damage to the remaining surfaces.

Comments:

3.6. prepared the panel flanges, the replacement panel and the backing plate edges to receive adhesive and mechanical fixings.

Comments:

3.7. dry fitted the replacement panel section and the studded backing plate and checked the alignment / measurements.

Comments:

3.8. located the adhesive work-time and prepare the material and application equipment.

Comments:

3.9. produced an adhesive test bead.

Comments:

3.10. protected areas from corrosion, (where required) and applied the adhesive in accordance with the manufacturers specifications.

Comments:

3.11. fitted and aligned the replacement panel section and studded backing plate and secured them using the correct clamping, bonding and mechanical fixing processes.

Comments:

3.12. removed the excess adhesive and achieved an acceptable cosmetic finish prior to curing it.

Comments:

3.13. identified if any of the joints were not correctly formed and took the necessary action.

Comments:

3.14. alerted others to the curing process with notices or signs.

Comments:

3.15. located the curing times and cured the bonding material as specified in the manufacture's recommended methods.

Comments:

3.16. used the correct tools throughout the assessment process.

Comments:

3.17. cleaned and stored the tools and equipment correctly.

Comments:

3.18. maintained the cleanliness and safe working conditions of the work area throughout the task.

Comments

3.19. completed final quality checks and inspections.

Comments:

3.20. worked safely and in accordance with the current safety legislation throughout the assessment.

Comments:

3.21. completed the assessment within the agreed timescale.

Comments:

3.22. recorded information which is required for assessment process.

Comments:

3.23. completed the required knowledge assessment.

Comments:

Assessor comments:

Add comments so accurate feedback can be given to candidate, this may include photographic / recorded evidence of the observed assessment.

Assessor’s signature:

PASS / REFERRED

Assessor’s PIN:

(Page 14) (Issue 1.1) (© Institute of the Motor Industry, Fanshaws, Brickendon, Hertford SG13 8PQ, UK)