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Ford, Alcoa announce next generation of aluminum lightweighting for F-150

Ford likes what it has seen with the use of aluminum in its world-beating F-150 pickup trucks. Now, the Blue Oval is working with Alcoa to use that company's Micromill material to increase the amount of aluminum in Ford vehicles. In fact, Ford will start using Micromill on 2016 model-year F-150s later this year, and will double the material's use in 2017. The purpose, as you might suspect, is light weighting, which allows Ford to boost towing capacity while adding as little weight as possible. Ford will be the first automaker to use Micromill, and will use it in both structural components and exterior panels. Micromill's rolling-mill system cuts the time it takes to turn molten metal into coil to 20 minutes from about 20 days. Already, Ford has had positive results by using aluminum on its leading pickup truck model. In April, it was announced that the 2015 Ford F-150 achieved a five-star Overall Vehicle Score in the National Highway Traffic Safety Administration's testing. Safety features like inflatable seat belts, adaptive steering columns and a forward collision warning system helped matters. General Motors may have taken note of those results, even after running an ad campaign touting its continued use of steel over aluminum. Last month, GM said it would sink $877 million into its Flint, MI, truck factory. Reuters said much of the expense was to convert many of the bodies for models like the Chevrolet Silverado and GMC Sierra pickups into aluminum. You can take a look at Ford's press release below. Ford Motor Company and Alcoa Inc. are collaborating to produce next-generation automotive aluminum alloys that are more formable and design-friendly. Ford will use Alcoa's Micromill® material in multiple components on the 2016 F-150 – becoming the first automaker to use the advanced automotive aluminum commercially. The companies entered into a joint development agreement to collaborate on next-generation aluminum alloys for automotive parts using Micromill™ technology. ''Light-weighting enables us to design vehicles with great customer attributes – like the F-150, which can tow more, haul more, accelerate quicker and stop faster than the previous F-150, and is more fuel-efficient than ever," said Raj Nair, Ford group vice president and chief technical officer, Global Product Development.

70% of pickups could use aluminum by 2025

In the next decade, the auto industry will see an explosion in its use of aluminum to cut weight and increase fuel economy, according to a study from market analysts Ducker Worldwide cited by The Detroit News. We are already seeing the lightweight metal show up extensively in luxury models from Europe, but with the impending launch of aluminum-intensive 2015 Ford F-150 (pictured above), North America is using it even more, as well. The report predicts 70 percent of US pickups to have aluminum bodies by 2025.
It won't just be pickups that see the benefit, though. The average amount of aluminum in US vehicles is forecasted by the study to grow from an average of 350 pounds in 2013 to about 550 pounds by 2025. The most common parts to use it will be hoods, doors and - to some extent - roofs, as well.
The massive increase in pickups' aluminum content hardly seems surprising. The F-150 is predicted to use so much that it might cause a short-term shortage, according to one earlier report. At the same time General Motors is heavily rumored to be negotiating with suppliers for the next generation Chevrolet Silverado and GMC Sierra. Ram is the last holdout of the Big Three, but the study predicts that not to last.

2020 Ford Explorer nabs IIHS Top Safety Pick+ rating after updates

The 2020 Ford Explorer has been named a Top Safety Pick+ by the Insurance Institute for Highway Safety, the agency's best rating. The redesigned Explorer initially fell short of that mark, however, only making the grade after Ford introduced a running change to the vehicle's design starting in May 2020 — a change made to the 2020 Lincoln Aviator as well. To achieve a Top Safety Pick+ award, a vehicle must have a Good performance rating in all six of the agency's crash tests. It also must have Acceptable or better ratings for all of its available headlamps and must earn Advanced or Superior ratings for its automated collision avoidance systems in tests of their performance against pedestrians and other vehicles. The 2020 Explorer initially achieved only an Acceptable performance in the IIHS's driver's-side small-overlap crash test, as the agency found a risk of injury to the driver's left foot due to intrusion into the footwell. Ford subsequently modified the design of the front subframe in a running change to Explorers and to Lincoln Aviators built after May 2020. The modified Explorer was re-tested, and this time the model achieved a Good performance in the driver's small-overlap test. That, combined with a Superior performance in both tests of the standard collision-avoidance system plus Acceptable ratings for both headlight systems, pushed the 2020 Explorer over the goal line to Top Safety Pick+. The Aviator, which shares the Explorer's platform, has received the same modification and achieves the same crashworthiness ratings. However, its standard headlights are judged Marginal, and therefore the 2020 Aviator achieves only the Top Safety Pick rating (even though its optional curve-adaptive LED headlights are judged Good). Related Video: