Ford F-150 2015 - Extrusions

Module�2�-�AluminumTextbook
2015�Ford�F-150�Structural�Repair�Training�Course�(FOR06) 22
aluminum�panels.�Even�structural�parts,
such�as,�the�B-pillar,�are�made�from
stampings.
Creases�or�tears�in�a�panel�generally�requires�panel
replacement.
Though�stampings�have�the�most
repair�options�of�all�aluminum�parts,
when�deciding�if�a�stamping�should�be
straightened,�consider:
• if�the�part�should�be�straightened
with�the�use�of�heat.�Small�("small"
being�subjective�to�the�repairer)
damage�generally�can�be�reduced
or�removed�without�the�use�of
heat.�When�removing�damage,
heat�will�always�make�damage
removal�easier,�but�the�heat�may
damage�the�coatings.
• if�heat�is�being�used,�Ford�limits
the�use�of�heat�to�425°F.�As
long�as�the�heating�limits�are�not
exceeded,�there�is�no�cumulative
time�limit�for�the�use�of�heat.
• the�effects�of�the�part�stretching.
Even�though�heat�will�reduce�the
amount�of�stretching,�aluminum
will�not�react�like�steel,�and�oil
canning�may�occur.
Extrusions
This�six-cell�extrusion�is�an�example�of�a�multi-cell
extrusion.
Extrusions�are�made�bypushing�heated,
solid�aluminum�billets�through�heated
dies.�It�is�sometimes�pulled�as�it�exits�the
die�if�the�extrusion�must�be�straight.�A
simple�example�of�extruding�is�pushing
adhesive�out�of�a�tube�or�cartridge.�The
adhesive�tip�serves�as�the�die.
Unique�characteristics�of�extruded�parts
include:
• no�pinchweld.
• there�may�be�an�attachment�flange
on�the�part�which�looks�like�a
pinchweld,�but�is�designed�to�have
parts�riveted�or�welded�to�it.
• complex�designs�and�shapes�with
seams�that�are�not�visible.�An
extrusion�may�have�a�variable
thickness�cross�section.�This�is
done�by�varying�the�openings�in
the�die�when�the�part�is�being
extruded.�Extrusions�are�made
from�a�continuous�form,�either
straight�or�curved.�If�a�part�is
curved,�it�may�be�curved�in�a
post-forming�operation.The
rocker�panel�reinforcement