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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.

Ford recalls 125,000 Maverick, Escape, Corsair hybrids over fire risk

Ford is recalling more than 125,000 Maverick, Escape and Lincoln Corsair hybrids produced for the 2020-2023 model years to address a fire risk associated with failure of their internal combustion engines, which Ford says is happening with undue frequency. In the event of an engine block breach, oil and fuel vapors may collect under hood in places that would make them prone to ignition, meaning that an engine failure can do more than leave owners stranded.  "Isolated engine manufacturing issues have resulted in 2.5L HEV/PHEV engine failures involving engine block or oil pan breach," Ford said in its defect report to NHTSA. "In the event of an engine block or oil pan breach, the HEV/PHEV system continues to propel the vehicle allowing the customer to continue to drive the vehicle. As the customer continues to drive after a block breach, oil and/or fuel vapor continues to be expelled and accumulates near ignition sources, primarily expected to be the exhaust system." Per Ford, the "manufacturing issues" include poor machining of the engine crankshaft and contamination of engine block mating surfaces during assembly. The issue has been fixed in production, but 2.5-liter engines that escaped the factory with defects could be ticking time bombs. Ford's solution is to re-work the underhood components that allow combustible liquids and vapors near ignition sources. This way, the cars are better protected against immolation regardless of the circumstances. Signs of failure will be obvious, Ford says. Loud clanging or booming noises, a loss of power and smoke are all immediate signs that the customer should exit the roadway as safely and quickly as possible and shut the car down.  Owners should expect to receive notifications by the end of June or early July. They should begin circulating by mid-month. All remediation will be handled for the customer free of charge by their Ford dealerships.  Related video: This content is hosted by a third party. To view it, please update your privacy preferences. Manage Settings. 2020 Ford Escape Hybrid and Plug-In Hybrid

Xcar gets the scoop on Ford's strategy for the GT at Le Mans in 2016

Ford's plan to return to the 24 Hours of Le Mans in 2016 with the latest GT might have been one of the worst kept secrets in motorsports in recently memory. Even before the road car debuted at the 2015 Detroit Auto Show, rumors were flying about the Blue Oval's strategy. The wait for the official announcement just before this year's race was certainly a long one, but it was probably worthwhile just to see the competition version's spectacular looks. Xcar recently got the chance to interview Ford about the company's objectives for the new racer's development. Both the GT racing and street programs are meant as ways to advance cutting-edge technology and potentially let it trickle down to less-expensive models in the future. This is especially the case when it comes to finding ways to make carbon fiber cheaper and better. Of course, the supercar is also a showcase of what Ford can do competitively, and apparently there are patent-pending suspension parts the company isn't even talking about yet. Ford would love to score a class victory at Le Mans next year, and is pretty clear here and in its earlier promo video that it sees Ferrari as a major rival in the race. While that makes sense historically, the cross-town competitors at Corvette could be an even bigger challenger. That squad has a more recent legacy of success in the 24-hour challenge, including a victory in the GTE-Pro class this year. Related Video: