Mark Keller, Manager Truck Structure

Michael Danyo, Aluminum Technology Specialist

� Why an aluminum?

� Recent history of AIV’s at Ford.

� Overview of the BIW.

� BIW Joining Technologies.

� BIW Fastening Technologies.

� Reduce Mass

◦ Improved Fuel Economy.

◦ Improved Payload.

◦ Improved Performance and Feel.

◦More saleable content.

◦Additional secondary weight saves.

� 40%+ weight save over outgoing BIW.

� 14 Material Specifications.◦ Includes in house hydroforming of front

end and roof rails tubes.

◦ In house heat treat and batch pretreat operations.

� 8 BIW joining technologies.

� 6 BIW fastening technologies.

2015 F150

� Self-Piercing Rivets -Henrob

� Structural Adhesive-Dow

� Flow Drill Screws-Semblex/Ejot/Weber

� Clinches-Tox

� Resistance Spot Welds-ARO

� Laser Weld-IPG

� Friction Welds-Coldwater

� Bolts

� Two feed systems:◦ Spool◦ Cartridge-Bulk fed

from hopper.

� Servo Setters (all Henrob).

� Inspection:◦ In-Process Control◦ Visual and

Measurements by Inspectors

� Extensive upfront Feasibility.

� Two Diameter Rivets used:◦ 3mm◦ 5mm

� Lengths range from 4 mm to 11 mm.

� Tubular and Semi-Tubular.� Several head variations of

Countersunk and Pan Head.

� Prefers thin to thick, but can tolerate ratios down to 1/3.

� Used in mixed metal joining.

� Using about 110 m average per truck.

� Dow 6160.

� Using Alcoa 951 pretreatment.

� Used in combination with:◦ SPR

◦ FDS

◦ Clinches

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� Using about 140 FDS on average per truck.

� Using only two lengths of screw.

� One-sided joining.

� Requires stiff area.

� EJOT style screw produced by Semblex.

� Six steps during the install process.

� Clearance holes are sometimes required depending on gauge and alloy of materials.

� Weber equipment.

� Use about 70 TOX clinches average per truck.

� Typically used in conjunction with other joining methods.

� Process prefers thick to thin.

� Used as a mixed metal joining method.

� About 100 RSW average per truck.

� Used on the box floor for more robustness to corrosion.

� Ford developed / patented process.

� ARO controller and guns.

Resistance Spot Welds • 98 RSW’s/veh• 51.4 million/yr

Resistance Spot Welds • 98 RSW’s/veh• 51.4 million/yr

� About 6 meters average length of laser welding.

� All edge welding.

� AA4047 Filler wire.

� IPG with Highyaghead.

� About 8 friction weld applications per vehicle.

� Use a Harmes & Wende Tool

� Primarily used to attach “Crush” tubes.

2015 F150

� Used a combination of RB&W, Arnold, Strux and Profil.

� Proven technology in used in our aluminum closures.

� Developed designs with Maclean-Fogg

� Used in BIW grounding applications.

� Currently all M6 unthreaded applications.

� Used throughout the vehicle in aluminum and steel.

� Prog die part.

� M6 though M12 used on truck.

� Threaded and unthreaded.

� Used on internally installed bodyshopgrounding applications.

� M8 and M10’s.

� Stanley supplies studs and equipment.

� Used on typically on our hydroformed front end tubes for light duty (M6) attachments.

� Benefit is that an extra hole or fastener does not need to be added to the tubes saving costs in cycle time and fastener cost.

� Need to tune the bit diameter based on application-Supplied by Flowdrill.

� The joining and fastening required for and AIV is different and unique.

� The balance of each joining/fastening method will change based on alloys, form (castings, stampings, hydroforms, etc) along with new developments, supplier performance and lessons learned.

� Engineers will need to understand the benefits and drawbacks of the joining and fastening processes.

� Many tools and fasteners are engineered products and not commodities.

� Elizabeth Hetrick, Bill Moision, JoAnn Clarke, Aindrea Campbell, Amanda Freis, Juergen Hover, Ted Coon, Arnon Wexler, Steve Kernosky, George Luckey, Nia Harrison, Jina Kim, Doug Rehkopf, Larry Dupuis, Kim Lazarz, John Hill.

� Also the PD Sheetmetal team, VO-BCE Team and all our suppliers.