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Aluminum Ford F-150 earns five-star crash rating [w/video]

The scores are in, and the 2015 Ford F-150 has been awarded a five-star Overall Vehicle Score in the National Highway Traffic Safety Administration's testing. That makes it, according to Ford, the safest F-150 ever. "The five-star safety rating is a terrific example of One Ford collaboration and innovation," Vice President of Global Product Development Raj Nair said in a statement. "Our truck team worked together for years to deliver this accomplishment, using an unprecedented combination of advanced materials throughout the all-new F-150. The 2015 model is engineered to be the safest F-150 ever, which matters to customers who depend on this truck to not only get the job done, but also get them safely home." The new F-150's aluminum and high-strength-steel construction posed some unique challenges to truck's engineers. "The team had to invent new ways to manage crash energy, because advanced materials like high-strength steel behave differently," Matt Niesluchowski, the truck's safety manager. "We found that changing certain shapes led to a weight reduction, while also improving crash performance." Beyond the structural safety features, the 2015 F-150 is loaded with additional safety features, including an adaptive steering column and Ford's inflatable seat belts, that protects drivers in the event of a collision. Beyond that, there's the usual array of active safety features meant to prevent a crash in the first place, including Curve Control and forward collision warning with brake support. Check out Ford's full press release on its five-star score, as well as video on the truck's safety features.

How Ford switched gears for the all-new F-150

Editor's Note: This story is authored by Julia Halewicz, a senior editor with AOL's Custom Solutions Group. She holds a Masters in Journalism from NYU and has spent her career as an editor of various newspapers, magazines and digital outlets. Last year on the Friday before Labor Day, the 2014 Ford F-150 pickup truck came off the Dearborn assembly line for the last time. After the last seam was welded, the F-150 that had been so beloved by American consumers would begin the transition from traditional steel manufacturing to an aluminum body, and the second phase of Ford's 2007 blueprint for sustainability would begin. Jobs would be created, and Ford would deliver a stronger product to its consumers. It was a moment Ford would call the biggest in the company's 111-year history. Breaking The Mold For some, the change was almost unfathomable. How could a truck be made with aluminum, and why change what clearly was working very well for the company? "We have a saying at Ford that leaders lead," said Doug Scott, the company's truck group marketing manager. "This was an ideal product to make with aluminum-alloy, because lightweighting made so much sense for a truck, because the extent to which you could take weight out of a truck, you could add more value to the customer in terms of more towing, more payload, more durability, more efficiency – so again all this required us to be out in front further out in front that we normally would be to make sure that we would deliver on all those expectations." Ford began the planning process about five years before the first aluminum F-150 would come to market. The company had a lot of questions. What was customer acceptance of aluminum, could they build the truck, and could the truck be repaired out in the field? Finally, Ford needed to determine if there were enough materials available to support the demand for the F-Series. Aluminum vehicles aren't unusual, but had never been built on the scale of the F-150 – approximately one every minute. Ford created two prototypes to determine if the product would meet and exceed consumer expectations. Any change to the vehicle had to be justified in performance, safety and economy. An aluminum truck needed to be safer, lighter, have increased payload, haul more, and have improved fuel efficiency. After driving the prototypes, Ford knew it was ready to move forward. Once the aluminum truck was ready to build, the next challenge was quickly transforming the plant.

The biggest gas-guzzlers of 2024: 'The Meanest List' is the opposite of greenest cars

In some circles — especially some automotive circles — bigger is better. This explains the Hummer, for example. In its so-called “Meanest List” of a dozen models, the American Council for an Energy-Efficient Economy (ACEEE) makes no apologies for berating “the worst-performing mass market automobiles” sold in 2024 in the U.S. The most diminutive car on the list is a Chevy Corvette Z06. At the top of this particular heap is the Mercedes-Benz AMG G63, a gas-powered SUV that the environmental agency says was “the worst-performing vehicle of the more than 1,200 models assessed by Greener Cars and has an annual fuel cost over $4,000.” Not to mention its MSRP of around $184,000. Rank Make & Model Powertrain Green Score MSRP Estimated Annual Fuel Cost* 1 Mercedes-Benz AMG G63 Gas 20 $184,000 $4,242 2 Ram 1500 TRX 4x4 Gas 22 $98,335 $3,819 3 Ford F150 Raptor R Gas 24 $79,975 $3,777 4 Cadillac Escalade V Gas 26 $152,295 $3,388 5 Dodge Durango SRT Gas 26 $74,995 $3,332 6 Jeep Wrangler 4dr 4X4 Gas 27 $35,895 $3,260 7 Jeep Grand Wagoneer 4x4 Gas 28 $91,945 $3,058 8 Mercedes-Benz G550 Gas 28 $143,000 $3,186 9 GMC Hummer EV SUV EV 29 $98,845 $1,746 10 GMC Sierra Gas 29 $37,700 $3,069 11 Chevrolet Corvette Z06 Gas 30 $114,395 $3,169 12 Mercedes-Benz Maybach S680 Gas 30 $234,300 $3,031 *ACEEE analysis using EIA data of the annual cost of driving 15,000 miles In terms of numbers, the dirty dozen of the meanest includes seven SUVs and three trucks. Lonely at the middle of the list is the sole electric, the GMC Hummer EV, which weighs in at 9,000 pounds. The council notes that “though EVs have lower emissions than similarly sized gasoline models, the Hummer demonstrates that size and efficiency, not just fuel source, are important factors in a carÂ’s environmental impact.” ItÂ’s also worth reminding prospective buyers that the average fuel cost of a vehicle on the “Greenest List” eats up only a fifth of the fuel cost of a vehicle on the Meanest List, “showing that greener options can also be more affordable.” The ACEEE also put out a "Greener List" of efficient gasoline and hybrid cars that don't require plugging in.  By the Numbers Green Cadillac Chevrolet Dodge Ford GMC Hummer Jeep Maybach Mercedes-Benz RAM Emissions Fuel Efficiency Green Automakers Truck SUV Electric Hybrid