I-CAR Non-Structural flashcards

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

Unibody load path

A welded structure of rails, rockers, and pillars that carries crash and suspension loads; outer bolt-on or welded panels usually contribute appearance and minor stiffness rather than primary structural function.

Boron UHSS repair restriction

Ultra-high-strength boron steel in pillars and rockers typically cannot be heated or sectioned; OEM procedures usually require replacement of the entire part or an approved partial part.

Body-over-frame construction

A design in which a separate steel ladder frame carries crash and payload loads while the body mounts to it through rubber isolators, allowing body removal and frame straightening separately.

Spot weld cutter sizing

The cutter diameter should match the original weld nugget so the replacement weld can be placed in the same location without an oversized hole that reduces weld strength.

Panel gap measurement

Gaps are measured with a gauge at consistent reference points and compared side to side or to OEM specifications before permanent attachment of the replacement panel.

Door alignment sequence

Hinges are adjusted first to set the rear gap and beltline, then the striker is positioned for flushness; forcing the striker cannot correct hinge misalignment.

Adhesive flange preparation

Residual adhesive, weld nuggets, and sealer are removed and the flange is flattened and coated per OEM specification before new adhesive or welds are applied.

Oil canning cause

A panel that pops in and out has residual stress from rough straightening; controlled hammer-on-dolly work relieves the stress before finishing begins.

Paintless dent repair limits

PDR applies to accessible dents with intact paint and no stretched metal; sharp creases, stretched crowns, and damaged coatings require conventional repair methods.

Aluminum work hardening

Aluminum panels harden and crack with repeated bending and lose strength at low heat, so dedicated tools and strict temperature limits are required during repair.

Plastic identification code

A molded code on the back of a plastic part identifies the substrate, which determines whether plastic welding, adhesive repair, or replacement is appropriate.

Squeeze-type spot welding

Resistance spot welding with pincer electrodes reproduces factory welds on steel; nugget quality depends on clean mating surfaces, electrode force, and correct current settings.

MIG brazing characteristics

A low-heat joining process using bronze filler on galvanized and high-strength steel; it is not a fusion structural weld and cannot replace welds the OEM specifies as full fusion.

Adhesive bondline control

Bond strength depends on uniform adhesive thickness maintained by glass beads or spacers, plus full cure at the product's specified time and temperature before loading.

Galvanic corrosion isolation

When aluminum contacts steel, moisture creates a galvanic cell; OEM isolation coatings, barriers, and dedicated fasteners must be used at mixed-metal joints.

Cavity wax application

Inner-panel coating sprayed into enclosed box sections after welding or sectioning protects surfaces that exterior primers and sealers cannot reach, preventing internal rust.

Seam sealer function

Sealer applied over primed seams replicates factory water barriers and appearance; it must be compatible with topcoat products and tooled to OEM coverage.

Filler substrate requirement

Body filler bonds only to properly prepared bare metal or an OEM-approved primed surface; applying it over paint, rust, or e-coat scratches causes adhesion failure.

Torque-to-yield fastener rule

Fasteners designed to stretch during tightening cannot be reused; they are replaced with new OEM-specified fasteners and tightened to the published torque and angle.

Hinge shim documentation

Shim locations and counts are recorded before removing a bolted panel so the replacement can be installed at the original position and adjusted from a known baseline.

One-time-use clips

Retention clips and weatherstrips are commonly single-use; reusing them causes rattles, wind noise, and water leaks that appear after the repair is delivered.

Windshield urethane bead

The adhesive bead width, location, and urethane type must match OEM specification because the bonded glass contributes to roof crush resistance and occupant retention.

Safe drive-away time

The adhesive manufacturer specifies how long a vehicle must sit before driving; the time varies with temperature and humidity and must be documented before release.

Windshield bracket and ADAS

Camera brackets bonded to the glass must match the original position and angle, because a shifted bracket can prevent successful recalibration of the forward camera.

Plastic welding rod match

Thermoplastic bumper covers are welded with rod material matching the molded substrate code; thermoset plastics cannot be welded and require adhesive repair instead.

Bumper energy absorber reuse

Many bumper energy absorbers and reinforcements are designed for one crash; after impact they are replaced rather than straightened to preserve energy management.

Sensor bore geometry

Repair material or coating buildup around radar and ultrasonic sensor openings can block or distort signals, so the original opening geometry must be preserved.

Radar sensor alignment

Radar units align to the vehicle centerline and are affected by bumper cover thickness, metallic coatings, and repair materials placed over the sensor face.

Static versus dynamic calibration

Static calibration uses targets placed at specified distances in a controlled area; dynamic calibration requires driving the vehicle at defined speeds and conditions to complete the process.

Recalibration triggers

Glass replacement, bumper replacement, suspension or ride height change, wheel alignment, and sensor removal or replacement commonly require ADAS recalibration per OEM procedures.

Pre-repair and post-repair scan

Scanning before repair records existing codes and faults; scanning after repair confirms no new codes and documents that systems were restored before delivery.

Repair record contents

Documentation includes VIN, mileage, materials and attachment methods, product batch numbers, weld counts, scan results, and calibration confirmations for verification.