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Automakers' rush on aluminum may result in shortage

Aluminum is the new buzzword in the automotive industry. The latest Range Rover and Range Rover Sport both take advantage of the lightweight material to shave huge amounts of body fat (only it's called "aluminium" over there). Audi and Jaguar have been using the stuff for years in their A8 and XJ, respectively, and now, aluminum is going mainstream, arriving on the 2015 Ford F-150.
While we're excited to see aluminum make an impact outside the premium market, its widespread adoption apparently won't come without some problems, notably in terms of supply. "There isn't an automotive manufacturer that makes vehicles in North America that we're not talking to," Tom Boney, of Novelis, the largest global supplier of aluminum sheetmetal, told The Detroit News.
According to Boney, Ford's use of aluminum on such a large scale has forced auto manufacturers in "every boardroom" to reconsider their plans following the F-150's unveiling, for one simple reason: there's not exactly enough aluminum to go around, at least in the short term. The auto industry presently only accounts for six percent of the aluminum sheet produced, but as the material is adopted by more and more brands, that figure is expected to swell to 25 percent within the next six years.

Shelby GT350R offers first mass-produced carbon fiber wheels

In the world of race engineering, reducing total weight is good, but reducing unsprung weight is flippin' fantastic. That's the reason Ford is pushing the envelope in terms of technology for the Shelby GT350R's wheels. Joining the likes of Koenigsegg in the offering, Ford has teamed with Australian outfit Carbon Revolution to produce the CF rollers en masse for the first time. Destined for the hubs of the new Shelby GT350R, the new hoops weigh just 18 pounds each, versus the 33-lbs weight of a similar aluminum wheel. On top of slashing up to 60 pounds in unsprung weight, there's such a reduction in rotational inertia – 40 percent, versus aluminum wheels – that Ford actually has to recalibrate the magnetic ride control system and springs. Thanks to, we're guessing, scenes of crashed Formula One cars disintegrating and spewing shards of carbon fiber all over the track, Ford seems quite keen to do away with the idea that CF is strong, but brittle. The company conducted extensive shock testing, ramming a wheel into a curb at speed. According to the Blue Oval, the lightweight wheel allowed the suspension to respond so quickly that the impact was "greatly diminished," causing the tester to run the experiment again, thinking there'd been a mistake. After recording brake rotor temperatures of 900 degrees Celsius (over 1,650 degrees Fahrenheit, or well past the point that aluminum or magnesium would melt) during testing, Ford and Carbon Revolution actually redesigned the wheels to "a thermal standard more suitable for motorsports," by adding an "incredibly thin, nearly diamond-hard coating that reliably shields the resin from heat." The same process was used to protect engine turbine blades on the Space Shuttle. While the work by Ford and Carbon Revolution should make GT350R customers excited, the work being done here could have serious implications for performance cars in the future. That's the real takeaway here, and is something that should leave fans of all performance vehicles excited.

Michigan ponders its automotive future in the connected age

Few people take cars more seriously than Michiganders. I've been to the home of BMW in Germany. I've been to Kia's HQ in Korea. I've seen Honda's goods in Japan. No one, from the factory worker to the executive in her pinstriped suit, is more obsessed with cars than Michigan Inc. That's why it was interesting this week to see the state have a moment of introspection four hours north of the Motor City on a scenic island called Mackinac. Ironically, cars are not allowed here. Normally a tourist trap, it played placed host to the Mackinac Public Policy conference this week. While politics took center stage ( I may be the only person here not considering a run for governor) the evolution of the industry through connectivity and data was a theme of the conference. If you're reading this in New York, Silicon Valley, or one of the automotive heartlands listed above, you do care about this. If Michigan rethinks its approach to the car business – and makes moves to become more competitive – that affects you the consumer and enthusiast. It's jobs. It's technology, and it's a competition to see who's going to be the leader. More than a century after Henry Ford made mass production a thing, more than 70 years after Detroit's Arsenal of Democracy helped win World War II, and nearly a decade after the historic bankruptcies of General Motors and Chrysler, the car business is on solid footing again and looking to the future. What's next? Michigan is still home to thousands of auto workers, tech centers (including gleaming facilities built by Toyota and Hyundai), and the headquarters of the three American carmakers. Just because the economy is good doesn't mean it's a given connected cars and mobility advancements are going to come from this state. A lot of it's not. Tesla, Uber, Lyft, Faraday Future, and other transportation mediums have spouted up other places. Michigan leaders and Detroit's carmakers understand this reality. Reflecting on the past means admitting the future is not a given, a key undertone this week in Mackinac. It's about using existing resources, like skilled labor, to move forward. "We do have the number of technicians and technical expertise here in this state," says Stephen Polk," conference chair and former CEO of auto data firm R.L. Polk & Co. To that end, Ford is placing increased emphasis on a division called Smart Mobility, which is an in-house unit focusing on autonomy, connectivity, and forward-looking ideas.