1971 Ford Bronco 4x4 on 2040-cars

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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).

NHTSA closes Ford F-150 EcoBoost acceleration probe

Typically when we report on the findings of an investigation from the National Highway Traffic Safety Administration, it's because the government body has discovered a safety issue and prescribed a recall. In this case, however, NHTSA has closed an investigation into a reported performance deficit without ever getting to the recall stage.
The issue revolves around the Ford F-150 - specifically those equipped with the 3.5-liter EcoBoost engine - of which some 360,000 were built in the 2011, 2012 and 2013 model years. After receiving an initial 95 complaints, NHTSA opened an investigation last May - almost a year ago - into the reported issue of reduced engine power under hard acceleration. The agency has since received a total of 525 such complaints, and Ford itself reported receiving over 4,000.
Together, NHTSA and Ford determined that the problem resulted from cylinders misfiring, an issue itself stemming from water getting into the charge air cooler (CAC) mated to the turbochargers. In particularly humid or rainy conditions, water was found to get into the CAC, causing some of the cylinders to misfire, which in turn triggered the ECU to disable those cylinders in order to protect the catalytic converter from damage.

Ford tweaking Model E dealer program to address dealer concerns

Ford's been working on its strategy and sales reorganization for a couple of years, the initiative that created the Blue (ICE), Pro (commercial), and Model E (electric) divisions. On the Model E side, part of continuous reworking of the EV arm has been in response to dealer lawsuits filed in numerous states, since Model E not only stipulated investments of anywhere from $500,000 to $1.2 million, the automaker initially wanted dealers to set no-haggle pricing, offer remote pickup and delivery for service appointments, and build chargers that would operate around-the-clock. Another big part of the tweaks to Model E is the continually unstable ground the entire electric project is built on. As part of understanding what dealers are facing and how to keep the electric wheels turning, Automotive News reports that the automaker held 11 meetings with dealers this year in six cities. Based on the feedback, more changes are coming to Model E as soon as next month.   During the roadshow, Ford told dealers to pause their investments into getting certified for Model E. This directive followed a corporate change in plans as Ford pulled investments in battery-electrics in favor of consumers' choice for hybrids. The head of Ford Blue — the internal-combustion-powered division that, with Ford Pro, has been paying the bills as Model E posts big losses — told AN, "We don't want them to make any decisions between now and the middle of June, when you can maybe have a more informed decision-making process based off what we work out with council in the next few weeks." One change has already been made public, the VP of EV programs telling an AutoNews business conference audience, “What weÂ’re finding is more dealers want to be involved in it and we donÂ’t want to be exclusive to just a handful, and so weÂ’re making a change where weÂ’re opening up that and not requiring as many certifications or investments for a dealer to participate in the EV revolution." Don't take that comment as a revelation; since the beginning, dealers complained about being excluded and needing to throw so much money at the program. Take that comment as Ford needing to find a better way in the "rapidly changing" environment. The official list of updates won't come until next month, when Ford meets its dealer council, and it should touch on topics beyond EVs.