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Aluminum lightweighting does, in fact, save fuel

When the best-selling US truck sheds the equivalent weight of three football fullbacks by shifting to aluminum, folks start paying attention. Oak Ridge National Laboratory took a closer look at whether the reduced fuel consumption from a lighter aluminum body makes up for the fact that producing aluminum is far more energy intensive than steel. And the results of the study are pretty encouraging. In a nutshell, the energy needed to produce a vehicle's raw materials accounts for about 10 percent of a typical vehicle's carbon footprint during its total lifecycle, and that number is up from six percent because of advancements in fuel economy (fuel use is down to about 68 percent of total emissions from about 75 percent). Still, even with that higher material-extraction share, the fuel-efficiency gains from aluminum compared to steel will offset the additional vehicle-extraction energy in just 12,000 miles of driving, according to the study. That means that, from an environmental standpoint, aluminum vehicles are playing with the house's money after just one year on the road. Aluminum-sheet construction got topical real quickly earlier this year when Ford said the 2015 F-150 pickup truck would go to a 93-percent aluminum body construction. In addition to aluminum being less corrosive than steel, that change caused the F-150 to shed 700 pounds from its curb weight. And it looks like the Explorer and Expedition SUVs may go on an aluminum diet next. Take a look at SAE International's synopsis of the Oak Ridge Lab's study below. Life Cycle Energy and Environmental Assessment of Aluminum-Intensive Vehicle Design Advanced lightweight materials are increasingly being incorporated into new vehicle designs by automakers to enhance performance and assist in complying with increasing requirements of corporate average fuel economy standards. To assess the primary energy and carbon dioxide equivalent (CO2e) implications of vehicle designs utilizing these materials, this study examines the potential life cycle impacts of two lightweight material alternative vehicle designs, i.e., steel and aluminum of a typical passenger vehicle operated today in North America. LCA for three common alternative lightweight vehicle designs are evaluated: current production ("Baseline"), an advanced high strength steel and aluminum design ("LWSV"), and an aluminum-intensive design (AIV).

2013-2017 Ford Explorer recalled over rear suspension issue, again

Ford is recalling about 375,000 Explorer SUV models built between 2013 and 2017 in North America to fix a potential defect in the rear suspension. In "North America states and provinces where corrosion is common," which we take to mean areas that experience harsh winters and heavily salted roads, "a fracture of the outboard section of the rear suspension toe link" is possible on affected vehicles. Ford says 350,000 of these models were sold in the United States and another 25,200 in Canada. This isn't the first time Explorers of this generation have been recalled for fractured toe links. Back in the summer of 2017, 1.2 million Explorer models were recalled over toe links that could fracture if subjected to "frequent full rear suspension articulation (jounce and rebound)." A little over a year earlier, 75,000 Explorers were recalled over, you guessed it, rear toe links that may not have been welded properly. It's not just Explorers that Ford has recalled over rear toe links. Earlier this year, the automaker issued a recall that covered nearly 230,000 Ford Flex, Taurus and Lincoln MKT models. All of these recalled vehicles ride on similar unibody underpinnings that Ford calls the D4 platform. We can't say whether these other D4-based vehicles will get another recall as the Explorer has. Ford says it is aware of as many as 13 crashes and six injuries attributable to the toe links covered under this most recent Explorer recall. Owners will need to visit their preferred dealership, which will "complete a torque inspection of the cross-axis ball joint and replace it as necessary," according to Ford. Related Video:

Ford GT concept adorns Forza 6 cover

Ford has rolled in to the Detroit Auto Show this week with a staggering array of performance machinery, including the new GT Concept, Mustang GT350R and F-150 Raptor. That's the exciting part. The thing is, that most of us won't have the opportunity to drive any of them, let alone really wring them out on the track. Fortunately, they'll all feature in the upcoming release of Forza 6. Not only that, but the new Ford GT will adorn the box cover as well. Featuring on the cover of the latest installment of what Microsoft (citing Metacritic ratings) says is "the highest-rated racing series of the past decade" would be a coveted place of honor for any automaker. The box art for the original version (at least the one first released in North America) featured a modified Acura NSX, followed by a Nissan 350Z drifter on Forza Motorsport 2, an Audi R8 on Forza 3, Ferrari 458 Italia on Forza 4, an SRT Viper on Forza Horizon, the McLaren P1 on Forza 5 and the Lamborghini Huracan on Forza Horizon 2. This, then, will be the first time a Ford will be the poster child for a new version of the popular game. With carbon-fiber construction, active aero and a twin-turbo EcoBoost V6 pumping out over 600 horsepower, it strikes us as a place well deserved by Dearborn's finest. Microsoft and Ford Unveil Ford GT as the Cover Car for "Forza Motorsport 6" Debuting Exclusively on Xbox One Ford's new line of performance vehicles will star in Microsoft's newest and most advanced racing game DETROIT – Jan. 12, 2015 – Microsoft, Turn 10 Studios and Ford unveiled their new collaboration today at the North American International Auto Show, announcing the all-new Ford GT ultra-high performance supercar as the featured cover car in the next iteration of the acclaimed racing simulation franchise for Xbox, "Forza Motorsport 6," launching exclusively on Xbox One. The GT serves as a technology showcase for Ford with its ultra-efficient EcoBoost engine performance, advanced aerodynamics and lightweight carbon fiber construction. It begins arriving in dealerships in select markets globally late next year. In addition, the companies revealed that Ford's performance vehicle line-up will appear in "Forza Motorsport 6." This includes the GT, Shelby® GT350 Mustang and F-150 Raptor debuted by Ford earlier today at the auto show.