ASE B3 Non-Structural Analysis & Damage Repair flashcards

33 cards. Read the term and the definition here. The deck at the top of this page is optional.

Direct damage

Damage at the point of impact, including the panel struck and the structure immediately behind it. Identified by crushed, kinked, or displaced metal at the contact area.

Induced damage

Secondary buckling or bending that spreads outward from the impact into adjacent panels and structure. Found by tracing misalignment beyond the direct damage zone.

Inertia damage

Damage caused by the vehicle's mass continuing in motion after impact, producing buckles remote from the contact point, often at the opposite end of the body.

Control point measurement

Comparison of body dimensions to OEM-specified reference points, typically with a tolerance of about plus or minus three millimeters, to detect structural movement.

Coating thickness gauge

Instrument that measures paint and filler depth. Magnetic types read steel only; aluminum, plastic, and composite panels require eddy-current or ultrasonic gauges.

Replace versus repair rule

A panel with a kink, a crushed reinforcement, or damage through a mounting point is replaced rather than straightened because its designed strength and crush geometry cannot be restored.

Door hinge adjustment order

Loosen the body-side hinge bolts to set the door fore/aft and up/down, then the door-side bolts to set angle and flush. The striker is adjusted last.

Panel gap and flush

The even spacing between adjacent panels and how closely their surfaces align. Most late-model vehicles specify roughly four to six millimeters gap with about one millimeter flush variation.

Striker adjustment

Final step in door alignment. The striker is positioned so the latch engages centered and the door closes with firm, even effort without binding or rattling.

Hinge wear symptom

A door that drops or sags when opened usually indicates worn hinge pins or bushings rather than an adjustment error, and the hinge should be replaced.

High-strength steel heat rule

Steel with yield strength above roughly 550 MPa generally must not be heated for straightening, because heat destroys the temper and reduces the designed strength.

Boron steel handling

Martensitic and boron steels are replace-only at many OEMs. They must not be sectioned or heated unless the OEM repair procedure explicitly permits it.

Squeeze-type spot welding

STRSW uses two electrodes to clamp and fuse panels, closely replicating factory welds. Preferred replacement method, matching OEM weld count and spacing.

Weld-through primer

Coating applied to mating surfaces before welding to protect the joint interior from corrosion. It conducts current so spot welds form properly.

Panel bonding adhesive

Two-part structural adhesive requiring a clean, abraded, properly primed surface and a specified clamp or cure time. It does not replace welds at structural joints.

Hammer and dolly

Technique for stretching and leveling metal; the dolly backs up the hammer blow. A slapping file or pick hammer is used to shrink stretched areas.

ISO plastic code

Molded code on the back of a plastic part identifying its base material. It determines whether the part can be welded or bonded and which rod or adhesive is compatible.

Plastic welding

Joining thermoplastics with hot air or airless equipment using a rod of the same base material. Not applicable to thermoset composites such as SMC.

SMC repair

Sheet molding compound is a thermoset composite repaired with resin and reinforcement, not welded. It cures chemically rather than melting when heated.

Flexibility additive

Agent added to refinish materials on flexible bumpers so the cured paint film flexes with the substrate instead of cracking under impact or movement.

Adhesion promoter

Coating applied to low-surface-energy plastics such as polypropylene and TPO to allow paint bonding. Required because these plastics resist normal paint adhesion.

Regulator normalization

Re-initializing a power window motor after battery disconnect or regulator replacement by cycling the glass fully up and holding the switch to relearn travel limits.

Window run channel

The weatherstrip-lined channel that guides the glass. Pinching or friction here is a common cause of slow window travel that mimics a failing motor.

Safe drive-away time

Minimum interval before the vehicle may be driven after windshield installation, set by the urethane adhesive manufacturer and typically at least one hour.

Windshield urethane bead

Continuous adhesive bead of specified width and height applied to a primed pinchweld and frit. The bond must be complete to restore structural and airbag performance.

Trim retaining clips

Single-use fasteners holding exterior trim. Most lose tension when reused, so replacement is required to prevent rattles or detachment.

Trim tape application

Adhesive-backed trim requires a clean surface, adhesion promoter, and pressure of about 15 to 20 psi rolled over the full length, plus dwell time before water exposure.

Emblem placement

Emblems and badges are located by pilot holes or a template. Position is measured and marked before removal so the original placement is restored.

Trim interference check

Verification that installed trim clears door swing, glass travel, and sensor fields such as parking and blind-spot systems before final installation.

Battery disconnect wait

Before working near airbag modules, disconnect the battery and wait the OEM-specified time, commonly one to three minutes, for the backup power to discharge.

Airbag module storage

Store an undeployed module face-up with the trim cover pointing away from people. Never aim the deployment side at a person or surface.

Squib probing caution

Never probe an airbag squib with a test light or ohmmeter unless the OEM procedure specifies it, because the current can deploy the module.

Restraint component replacement

After deployment, the airbag module, pretensioner, and control module are usually replaced together, along with the clock spring and any damaged sensors, per OEM procedure.