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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).

Ford recalls 300,000 Crown Vics over lighting module

The Basics: Ford is recalling 312,814 units of the Crown Victoria and Mercury Grand Marquis sedans from the 2003-2005 model years. They were built at the St. Thomas Assembly Plant between Oct. 3, 2001, and Aug. 2, 2005. Ford says 296,004 of those units are located in the United States, with another 14,714 in Canada and 2,096 in Mexico. The Problem: The solder joints on the lighting control module could crack, depriving the headlamps of the power they need to light the way ahead. That could increase the risk of a crash, particularly at night and in other low-visibility situations. Injuries/Deaths: Ford reports that it is aware of 11 accidents that resulted from the problem, leading to one injury described as "minor." The Fix: The manufacturer is instructing dealers to replace the entire lighting control module. If You Own One: Make sure your headlights are working before getting under way. If they're not, avoid driving under low-light conditions, including at night, in heavy precipitation, or in fog. Ford Issues Three Safety Recalls and One Safety Compliance Recall in North America DEARBORN, Mich., Dec. 22, 2015 – Ford Motor Company is issuing three safety recalls and one safety compliance recall in North America. Details are as follows: Ford Motor Company issues safety recall for certain 2003-2005 Ford Crown Victoria and Mercury Grand Marquis vehicles to replace lighting control module Ford Motor Company is issuing a safety recall for approximately 313,000 2003-2005 Ford Crown Victoria and Mercury Grand Marquis vehicles to replace a lighting control module. The solder joints on the module could crack and interrupt power to the headlamps – increasing the risk of crash at night. Ford is aware of 11 reports of accidents and one report of a minor injury related to this issue. Affected vehicles include certain 2003-2005 Ford Crown Victoria and Mercury Grand Marquis vehicles built at St. Thomas Assembly Plant, Oct. 3, 2001 through Aug. 2, 2005. There are a total of 312,814 vehicles that might be affected in North America, including 296,004 in the United States and federalized territories, 14,714 in Canada and 2,096 in Mexico. Dealers will replace the lighting control module at no cost to the customer. Ford issues safety recall for certain 2016 Ford F-650 and F-750 vehicles to replace rear air brake chamber Ford is issuing a safety recall for 177 2016 Ford F-650 and F-750 vehicles to replace the rear air brake chamber.

2015 Ford Mustang production starts in Flat Rock

Today's the day, Ford fans. Production has officially commenced on the sixth-generation 2015 Mustang at the company's Flat Rock, MI factory. As production ramps up, sales should kick off in the coming months.
The production news isn't just a bit deal for American fans. With the new Mustang getting a bespoke right-hand-drive variant, the pony car's worldwide availability has swollen to include 120 different countries, including its home nation.
"Mustang is and will continue to be an automotive icon," Joe Hinrichs, Ford's president of the Americas, said in a statement. "Expanding its availability globally affords our customers around the world the opportunity to have a true firsthand Mustang experience - one unlike any other."