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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 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.

Recharge Wrap-up: Ford 1.0L EcoBoost a hit in Europe; Build a tiny inverter, win $1 million

In Europe, Ford's 1.0-liter EcoBoost engine is the best-selling turbocharged gasoline engine. The three-cylinder motor powers 20 percent of new Fords sold in Europe. Earlier this year, it won its third International Engine of the Year award, and between January and June, it was sold in about 120,000 cars. So far this year, 38 percent of Fords sold in the Netherlands, 35 percent in Denmark and 32 percent in Switzerland have been powered by the 1.0-liter EcoBoost. The engine's turbocharger spins at 248,000 rpm, and provides 24 psi of pressure. The engine produces up to 138 horsepower, depending on the version. Read more in the press release below. When lithium-ion battery packs are retired from the road, remanufacturing, repurposing, and recycling are worthwhile options, according to a study by Mineta Transportation Institute. The study included a cost-benefit analysis of those three options, and found remanufacturing to be the best route. To get the most out of them, batteries should be tested and have their damaged cells replaced then put back to use. Repurposing is the second best option, using the remaining available charge for something besides cars. Recycling on its own isn't profitable, but it could make economic sense with "increased technological breakthroughs." Learn more at Recycling International or download the report here. A smaller inverter for EVs can win you $1 million. The Little Box Challenge is an open competition to build a power inverter with a density of at least 50 watts per cubic inch. Google and the Institute of Electrical and Electronics Engineers (IEEE) are offering the hefty prize to the team that builds the inverter with the highest power density within an enclosed volume of 40 cubic inches. Teams must register by September 30. Read more at Green Car Congress or learn more at the Little Box Challenge website.