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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).

Recharge Wrap-up: Ford's "snowtonomous" Fusion Hybrid, Porsche eyes battery makers

Bosch and Panasonic are vying to be the battery supplier for Porsche's electric sports car based on the Mission E concept. While Bosch's costs may be higher, its solution would offer simpler logistics. Panasonic is already well established as a battery maker, providing the packs for the Porsche car's rival, Tesla. "We're in the final stage of making a decision," says Porsche CEO Oliver Blume, declining to comment on specific manufacturers. Neither Bosch nor Panasonic provided comment. Read more from Automotive News. Renault will supply a fleet of 150 Renault Zoe EVs for a smart solar charging project in Utrecht, Netherlands. The project involves the installation of 1,000 EV chargers powered by 10,000 photovoltaic panels. The Renault Zoes would be used as part of a carsharing program powered by the solar chargers. Renault and its partners will also implement a vehicle-to-grid system to provide energy during peak demand from the solar chargers and connected EVs. Read more in the press release from Renault. Ford has been testing an autonomous Fusion Hybrid prototype that is capable of driving itself in snowy conditions. Ford uses 3D mapping to scan the drive route. Its LiDAR laser mapping can even detect single falling snowflakes. It collects and processes up to 600 gigabytes of data per hour, comparing its environment to saved maps, a process that helps establish location more precisely than GPS. In addition to the LiDAR systems, the car is also equipped with cameras and radar to help it navigate. Eventually, the car could even be able to clean off its sensors when it detects loss of performance from ice and dirt. Read more in the press release below. FROM AUTONOMY TO SNOWTONOMY: HOW FORD FUSION HYBRID AUTONOMOUS RESEARCH VEHICLE CAN NAVIGATE IN WINTER DEARBORN, Mich., March 10, 2016 – Driving in snow can be a slippery challenge, with the potential for one blizzardy gust to white-out your field of view – a situation faced by the majority of people in the United States. So if self-driving cars are to become a reality – and they almost certainly will – they must be able to navigate snow-covered roads. In its quest to bring self-driving vehicles to millions of people around the world, Ford reveals six facts about its technology that allows for a car to drive itself in snow. 1. Mapping the way: Ford first creates high-resolution 3D maps using LiDAR technology to scan the area its autonomous vehicle will later drive in the snow.

Ford updates Power Stroke diesel V8, strengthens F-450, tweaks King Ranch

Ford is giving its F-Series Super Duty trucks some upgrades for 2015, and we're happy to say that one of them is an improved Power Stroke diesel V8. Also, Ford is strengthening the top-of-the-line F-450 to handle more abuse. And if wild west-style luxury is your thing, the automaker has performed minor cosmetic updates to its King Ranch Edition trucks, as well.
The turbocharged 6.7-liter Power Stroke V8 is currently rated at 400 horsepower and 800 pound-feet of torque, and Ford only tells us the new and improved Power Stroke can "produce power beyond today's" engine. What, then, did Ford actually improve upon? First, the Blue Oval swapped in a new, larger turbocharger. The new Garrett GT37 turbine unit is 72.5 millimeters in diameter, eclipsing the old GT32's 64-mm diameter piece. Ford states output increases with the new turbo setup, but since the new turbocharger operates at a lower peak pressure than the old one, the automaker was able to eliminate the wastegate system and reduce the engine's complexity. Ford even redesigned the turbo's oil and cooling lines to make the powerplant simpler. A byproduct of the larger turbo is better engine exhaust braking, which is controlled manually by a button on the dashboard.
Ford claims the upgraded diesel engine is more powerful, more robust, more efficient and more refined than before.