Ford F-150 2015 - Castings

Module�2�-�AluminumTextbook
2015�Ford�F-150�Structural�Repair�Training�Course�(FOR06) 24
because�of�little�or�no�access�to�the
backside.If�allowed�by�the�vehicle
maker.Straightening�an�extrusion�may
be�done�with�or�without�heat.�If�heat
is�being�used,�do�not�exceed�Ford's
recommendations�of�425°F.�As�long�as
the�heating�limits�are�not�exceeded,�there
is�no�time�limit.
Sectioning�Or�Partial�Replacement
The�extruded�A-pillar�reinforcement�/�roof
rail�on�the�2015�Ford�F-150�Super�Crew
may�be�sectioned�above�the�B-pillar.
Castings
Various�castings�are�used�in�the�center�section�of�this
chassis.
Aluminum�castings:
• are�created�in�a�mold�that�is
usually�made�up�of�sand�or�metal
to�form�the�casting.�This�is�done
by�pouring�molten�aluminum
into�a�mold�or�injecting�molten
aluminum�into�a�mold�under
pressure.�The�aluminum�is�allowed
to�cool�and�harden,�then�the�cast
part�is�removed�from�the�mold.
• can�be�made�in�nearly�any�shape
or�wallthickness�variations�in
cross-section�and�length.�It�is�not
uncommon�to�see�a�cast�part�that
has�irregular�shapes�and�thickness.
• are�generally�machined�to�a
smooth�surface�for�attachment.
• are�generally�attached�to�other
parts�with�GMA�(MIG)�fillet�welds.
Castings�can�also�be�attached�to
other�parts�using�bolts�or�rivet
bonding.
• may�have�a�rough-textured
surface,�such�as�an�orange�peel.
• may�be�hollow�or�solid.�This
depends�on�the�function�the
casting�is�serving.
During�straightening,�this�casting�developed�a�crack,
which�is�not�repairable.
Cast�aluminum�parts�are�often�used�for:
• joints�where�multiple�parts�come
together.�On�some�applications,
these�are�called�cast�nodes.
• strut�towers.�It�is�becoming�more
common�to�see�strut�towers�made
from�aluminum�and�used�on�steel
vehicles.
• pillars.�Though�pillars�are
commonly�stamped�or�extruded,