Icar Post Test Answers PDF Details

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Form NameIcar Post Test Answers
Form Length115 pages
Fillable?No
Fillable fields0
Avg. time to fill out28 min 45 sec
Other namesfom01 post test, lsc04 post test, icm00 post test, icm00 post test answers

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Automotive Foams

®

FOM01-INMAN1-E

<![endif]>Module 1

IMPORTANT NOTICE

This material provides general directions for collision damage repair using tested, effective procedures. Following them will help assure the reliability of the repair.

I-CAR cannot accept responsibility for any individual repair, such repair. Anyone who departs from the instructions in neither personal safety nor the integrity of the repair of the of methods, tools, or supplies.

nor can it warrant to the quality of this program must first establish that vehicle is compromised by the choice

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 recommendations will provide the basis for a thorough, professional repair.

© 2005–2012 by the Inter-Industry Conference On Auto Collision Repair (I-CAR) All Rights Reserved

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Instructor Manual

Module 1

 

 

Class

1:04

A-1

MODULE 1–OVERVIEW OF AUTOMOTIVE FOAMS

Topic A. Foam Uses

Learning Objectives

Learning objectives for this module include:

explaining why foam is used in vehicles.

identifying where foam may be located.

identifying the different types of foam used in vehicles.

explaining the uses of each type of foam.

Learning objectives for this module include:

nexplaining why foam is used in vehicles.

nidentifying where foam may be located.

nidentifying the different types of foam used in vehicles.

nexplaining the uses of each type of foam.

Instructor Information

Before beginning the class, take a moment to explain to the students the recommended prior programs.

Other programs required for a Certif- icate Of Professional Development Through Training in Non-Structural I include:

•฀ Oxyacetylene/Plasma฀Arc฀Cut-

ting (WCS05).

•฀ Trim฀And฀Hardware฀(TRM01).

•฀ Cosmetic฀ Straightening฀ Steel฀

(STS01).

•฀ Bolted-On฀ Replacement฀ Parts฀

(EXT01).

•฀ Movable฀Glass฀(GLA01).

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Topic A. Foam Uses (cont'd)

Reasons For Foam In Vehicles

A-2

Foam is used in vehicles to:

n฀ reduce฀noise,฀vibration฀and฀harshness฀(NVH).฀ NVH฀may฀be฀caused฀by฀vehicle฀design,฀texture฀ of the driving surface, or air passing along the vehicle.

nrepair water leaks.

nstiffen the body structure and help control twisting and flexing of the vehicle.

nprovide collision energy management.

nprovide additional crash protection for occupant safety.

Instructor Information

Objectives Worksheet

Foam is used in vehicles to:

•฀ reduce฀ noise฀ vibration฀ and฀ harshness฀ (NVH).฀ NVH฀ may฀ be caused by vehicle design, texture of the driving surface, or air passing along the vehicle.

•฀ repair฀water leaks.

•฀ stiffen the body structure and help control twisting and flexing of the vehicle.

•฀ provide฀ collision฀ energy฀ man- agement.

•฀ provide฀additional฀crash฀protec- tion for occupant safety.

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Topic A. Foam Uses (cont'd)

Foam Locations

A-3

Foam฀Filler฀Locations

Foam may be located virtually anywhere on a vehicle. Some of the more common locations include:

nA-, B-, C-, and D-pillars.

nrocker panels and roof rails.

nframes and rails.

ncrossmembers.

nbetween the roof skin and roof bows.

nbetween the door skin and intrusion beams.

nquarter panels.

Instructor Information

Objectives Worksheet

Foam may be located virtually any- where on a vehicle. Some of the more common locations include:

•฀ A-,฀B-,฀C-,฀and฀D-pillars.

•฀ rocker฀panels฀and฀roof rails.

•฀ frames and rails.

•฀ cross฀members.

•฀ between฀the฀roof฀skin฀and฀roof฀ bows.

•฀ between฀ the฀ door฀ skin฀ and฀ intrusion beams.

•฀ quarter panels.

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A-4

Topic A. Foam Uses (cont'd)

NVH Control

Expandable foam is used to block and absorb sound waves from entering the cabin of a vehicle. Typically, the softer the foam, the better it absorbs sound. Foam is also used to fill and seal cavities to reduce wind noise, and to hold panels in place to prevent flutter or vibration.

Instructor Information

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A-5

Topic A. Foam Uses (cont'd)

NVH Control (cont'd)

Expandable฀ foam฀ that฀ is฀ used฀ for฀ NVH฀ control฀ is commonly located at multiple areas within a vehicle chassis. Areas where the vehicle maker installed foam should be noted during repair so the correct locations receive the proper amount of replacement foam. These foam installation loca- tions฀are฀critical฀for฀controlling฀noise.฀NVH฀foam฀ is not designed to affect the structural integrity of a vehicle.

Instructor Information

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A-6

Topic A. Foam Uses (cont'd)

Common Structural Foam Locations

Structural foam has limited applications. Structural foam is used for collision energy management and is very dense. Locations where structural foam is used include the:

nfront lower rails. The 2004–2005 Cadillac CTS and STS use a structural foam block in the front lower rails.

nA-pillars. The 2003–2004 Ford Expedition, Navigator, and Chevrolet SSR use structural foam in the A-pillar area.

nD-pillars. The 2003–2004 Ford Expedition and Navigator use structural foam in the D-pillar area.

nfull-frame torque box areas. The 2003 Ford Crown Victoria uses structural foam in the torque box areas of the frame.

Instructor Information

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Topic A. Foam Uses (cont'd)

Structural Enhancement

Structural foam is used to add rigidity and strength to the upper or lower areas of the vehicle. This limits the amount of twisting and flexing of an area, which helps control cracking and other damage from work hardening. This can also change the way a vehicle will perform in a collision.

STRUCTURAL FOAM

Instructor Information

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A-8

Topic A. Foam Uses (cont'd)

Structural Enhancement (cont’d)

Structural foam can change the characteristics of a vehicle. Structural foam:

nincreases strength and adds less weight than if additional steel were used.

nis typically used between engineering changes. With the use of structural foam, there is minimal disruption to the assembly process.

nis a highly dense material.

nhas minimal expansion.

Instructor Information

Objectives Worksheet

Structural foam:

•฀ increases฀strength of a part.

•฀ is฀typically฀used฀between฀engi- neering changes.

•฀ is฀highly dense material.

•฀ has฀minimal฀expansion.

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