Ford F-150 2015 - Module 4 - Body Design And Construction; Body Assembly Materials Overview

Module�4�-�Body�Design�And�ConstructionTextbook
2015�Ford�F-150�Structural�Repair�Training�Course�(FOR06) 55
Body�Assembly�Materials�Overview
Learning�objectives�for�this�module
include:
• describing�what�materials�are
used�at�different�locations�on�the
vehicle.
• explaining�what�repairs�can�be
done�to�the�magnesium�radiator
core�support.
• describing�how�close�to�a�hinge�or
striker�a�cut�line�can�be�for�repairs.
• explaining�the�repair�process�for
the�laminated�dash�panel.
• describing�the�repair�process�for
the�extruded�rocker�panel.
• describing�what�type�of
windshield�adhesive�is�required
for�stationary�glass�installation�on
aluminum�vehicles.
The�2015�F-150�should�be�repaired�in�a�designated
area�that�is�kept�clean�from�debris�that�could�cause
galvanic�corrosion.
The�aluminum�alloys�used�in�the�F-150
are:
• 6111�for�the�unitized�structure.
• 6022�for�the�exterior�panels.
The�radiator�core�support�has�been�made
of�magnesium�since�the�2004�model,�and
the�2015�F-150�will�also�be�magnesium.
Steel�is�used�in�several�areas�on�the
vehicle;�the�frame,�laminated�steel�cowl,
bumpers,�door�intrusion�beams,�and�door
hinges.
When�doing�repairs�on�the�2015�F-150,
repair�area�cleanliness�is�very�important.
Ford�recommends�that�aluminum�parts
and�vehicles�be�repaired�in�an�area
segregated�from�nonaluminum�(steel,
composite,�carbon�fiber)�vehicles�and
parts.�This�may�include�a:
• designated�repair�facility.
• curtained�off�repair�bay�/�area.
• designated�room.
According�to�Ford,�the�repair�area
used�for�a�2015�F-150�must�be,�at�a
minimum,�segregated�with�curtains.�These
recommendations�are�in�place�to�control
the�risks�of�galvanic�corrosion�from�fallout
caused�by�doing�repairs�on�steel�or�carbon
fiber�vehicles.
Ford�will�allow�the�aluminum�repair�area
to�be�used�for�repairing�nonaluminum
parts�and�vehicles.�When�aluminum
repairs�are�not�being�performed,the�area
must�be�thoroughly�cleaned�after�the
previous�vehicle�has�been�repaired.
Proper�workplace�cleanliness�will�ensure
no�nonaluminum�dust�or�particles�from
sanding,�grinding,�or�drilling�remain�in
that�area.