2008 Ford F150 Xl on 2040-cars

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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.

FCA to skip summer shutdowns as automakers rev up U.S. assembly lines

DETROIT — Several of FCA's facilities will skip their usual summer shutdowns to get a jump on rebuilding inventory, the company confirmed early Wednesday.  The plants that will remain open include three in the United States (Jefferson North in Detroit, Toledo Assembly in Ohio, and Sterling Heights Assembly in suburban Detroit), one in Canada (Brampton Assembly in Ontario) and two in Mexico (Saltillo Truck Assembly and Saltillo Van Assembly).  This will allow dealers to address depleted inventory of popular trucks and muscle cars, Automotive News reports. Other facilities not named will observe their normal one- and two-week breaks.  Automakers are speeding up U.S. assembly lines to meet recovering demand, increasingly confident coronavirus safety protocols are working to prevent outbreaks in their plants but wary of the challenges workers face outside. Screening workers for COVID-19 using temperature scans and questionnaires, the automakers have detected some people who reported for work despite being sick. Some plants have been briefly shut down for disinfection, but so far, there has not been a major outbreak within a U.S. auto plant since most reopened May 18, company and United Auto Workers union officials said. The risk of an infection picked up outside a plant spreading along assembly lines remains a prime concern, however. An outbreak could shut down a factory costing a manufacturer millions of dollars a day. The disruption caused by the pandemic is creating other challenges as well. At Ford Motor Co's F-series pickup truck plant in Louisville, Kentucky, the company has given more than 1,000 workers leave related to COVID-19 concerns. It hired temporary workers to fill their jobs as the plant accelerates production of trucks critical to Ford's financial recovery. Demand for pickup trucks helped boost U.S. auto sales in May, and contributed to stronger than expected overall U.S. retail sales for the month. Officials of UAW Local 862, which represents workers at the Louisville plant, said a lack of child care was a significant issue for members. It had led many to stay away from the plant and collect increased unemployment benefits provided under the federal CARES coronavirus relief act. Ford has now begun arranging subsidized child care for UAW workers, Gary Johnson, the automaker's head of manufacturing told Reuters.

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.