Ford F-150 2015 Structural Repair Training Course page 50

Textbook
never￿grind￿or￿sand￿with￿abrasives
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coarser￿than￿P80￿grit.
Practice￿welds￿should￿be￿completed￿before￿welding
on￿the￿vehicle￿using￿the￿same￿techniques￿and
materials.
When￿making￿practice￿welds:
duplicate the￿weld￿that￿will￿be
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made￿on￿the￿vehicle.￿Duplicate
the￿position,￿be￿it￿overhead,
vertical,￿or￿flat,￿and￿also￿use￿the
same￿material￿stack￿and￿alloy
material.￿When￿making￿practice
welds,￿it￿is￿also￿important￿to
duplicate￿the￿root￿gap￿and￿plug
weld￿size￿of￿the￿weld￿being￿made
on￿the￿vehicle.
use￿the￿recommended￿electrode
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wire.￿Ford￿requires￿ER5554,￿1.2
mm￿diameter￿wire. Only￿use
the electrode￿wire￿that￿is￿identified
by￿the￿vehicle￿maker.
remove￿any￿aluminum￿oxide.
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degrease￿the￿test￿material.￿Always
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remove￿any￿grease￿or￿oil￿that￿may
contaminate￿the￿weld￿area.
2015￿Ford￿F-150￿Structural￿Repair￿Training￿Course￿(FOR06)
Module￿3￿-￿Aluminum￿Joining￿Methods
Shown￿are￿coatings￿being￿removed￿with￿a￿stainless
steel￿wire￿wheel.
When￿preparing￿the￿vehicle￿and
replacement￿parts:
remove￿existing￿welds￿or￿coatings.
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straighten￿the￿flange.
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clean￿surfaces￿with￿wax￿and
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grease￿remover￿to￿remove￿any
contaminants.
clean￿both￿sides￿of￿both￿the
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vehicle￿and￿the￿replacement￿part.
When￿cleaning￿the￿weld￿joint
area,￿remove￿coatings￿50￿mm
away￿from￿each￿side￿of￿the￿weld
zone￿area.￿This￿includes￿paint
coatings,￿foams,￿and￿adhesive
residue.
do￿not￿use￿weld-through￿primer
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or￿any￿coatings￿in￿areas￿where
welding￿will￿occur.
ensure￿tight￿joint￿fit-up.
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ensure￿any￿backings￿that￿are￿being
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used￿contact￿both￿sides￿of￿the￿root
gap.￿This￿will￿help￿bridge￿the￿heat
between￿both￿panels￿and￿help
control￿heat￿distortion.
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