2009 Ford F150 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).

2021 Ford Mustang Mach-E, Volvo XC40 Recharge score high in IIHS tests

New electric cars continue their streak of impressive crash test results. The two latest to go through Insurance Institute for Highway Safety testing are the 2021 Ford Mustang Mach-E and the 2021 Volvo XC40 Recharge. The former earned a Top Safety Pick award, and the latter picked up the Top Safety Pick+ commendation. Both vehicles got the top "Good" rating in every crash test, as well as the "Superior" rating for vehicle-to-vehicle collision prevention. They deviate when it comes to headlights and vehicle-to-pedestrian collision prevention. Because the Volvo has headlights rated "Good" on all trims, it got that extra "+" on its Top Safety Pick award. The Ford also has high-rated headlights available, but the standard units got the second lowest rating of "Marginal." As for the vehicle-to-pedestrian collision prevention, the Volvo received the second-highest "Advanced" rating, while the Ford was rated "Superior." Among the electric cars IIHS has tested, the Ford and Volvo continue a streak of high scores. The organization has evaluated the Audi E-Tron in both its body styles, as well as the Tesla Model 3, both of which get the Top Safety Pick+ rating. As a result of the XC40 Recharge's test score, Volvo pointed out that it is the only automaker whose entire lineup has received a Top Safety Pick+ rating. Related video: This content is hosted by a third party. To view it, please update your privacy preferences. Manage Settings.  

2015 F-150 kick-starts Ford sales

The F-150 had a middling year in 2014, and its sales dipped slightly as Ford transitioned to producing the all-new truck with an aluminum body. But with one factory humming, another on the way and a fuller stock of trucks, 2015 is already shaping up to be a different story. The F-Series posted a 17-percent leap in January, helping to push Ford sales to a 15-percent gain for the month. The F-Series had its best January performance in 11 years with sales of 54,370 trucks last month. Much of this strength comes from the new generation of the F-150. While many of the old model are still being sold off, Ford is rolling out the new version. Just five percent of the F-150's retail sales were the new truck in December, but it was up to 18 percent in January. The increase comes as the first factory that makes the truck, Ford's Dearborn facility, is fully back online. The other F-150 factory, in Kansas City, is still completing its changeover to build the aluminum-bodied truck, and that's expected to be finished in the first quarter of this year. Sales of the truck will still be "tempered a bit" until the Kansas City plant ramps up, Ford sales analyst Erich Merkle said. Ford expects to have a full inventory of F-150s by mid-year. To that end, the company announced plans on Wednesday to add 1,550 jobs to support the F-150, including 900 positions at the Kansas City factory. The remaining jobs will be spread out over sites in metro Detroit. The Dearborn and Kansas City factories collectively will be able to build more than 700,000 F-150s annually. The added headcount also means Ford has reached the maximum number of entry-level workers allowed under its pact with the United Auto Workers. About 300 to 500 employees at several plants in the Midwest will transition to a higher pay rate, and their wages will rise from $19.28 an hour to $28.50 an hour. The F-Series was Ford's hottest seller in January, moving off lots in an average of 12 days. The high-end models, the King Ranch and the Platinum versions, are moving slightly quicker. The average transaction price is also up $2,100 for the F-150 compared to January 2014. "We're really pleased with how the new one is doing on dealer lots," Merkle said. A larger stock of F-150s will allow Ford and its rivals to capitalize on low fuel prices, which have slowed consumers' interest in smaller vehicles.