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Ford F-150 extended cab struggles in IIHS small overlap test

Update: Ford issued a statement to Autoblog to clarify the results of the test and dispute the IIHS repair cost estimates. A quote from a Ford representative has been added to the story. See the full statement below the IIHS press release. Of all the vehicles undergoing crash tests this year, few will be as closely watched as the new 2015 Ford F-150. That's not only because it remains the top-selling vehicle in America year after year, but also because it features an aluminum body instead of steel. While the F-150 performed well in the Insurance Institute for Highway Safety test, one factor prompted the institute to undertake a second round of testing that uncovered a problem. Like most full-size pickups, the F-150 is available in several cab styles: the regular two-door, the extended SuperCab and the four-door SuperCrew. The IIHS typically takes the most popular version of a particular model for testing, and in the Ford truck's case that meant the SuperCrew. The F-150 performed well in all the tests the IIHS put it through, including the small overlap test in which the vehicle is driven 40 miles per hour into a five-foot-tall barrier impacting the front left corner of the vehicle. Its overall performance in the tests earned the F-150 a Top Safety Pick rating, missing out on the higher Top Safety Pick + rating only because it doesn't have an automatic braking system. But how do the other versions of Ford's best-seller hold up? Given that even less popular versions of the F-150 still sell more than many other vehicles on the market, the IIHS put an extended cab through the same battery of tests. It performed comparably except in one area: the small overlap test. In that case, the extended cab model's steering column was pushed eight inches into the cabin (dangerously close to the crash test dummy's chest), the dummy's head missed the airbag almost entirely and hit the instrument panel, and the dummy's legs would risk sustaining "moderate" injuries. The reason for the disparity is that "Ford added structural elements to the crew cab's front frame to earn a good small overlap rating and a Top Safety Pick award but didn't do the same for the extended cab," according to the Institute's chief research officer David Zuby. "That shortchanges buyers who might pick the extended cab thinking it offers the same protection in this type of crash as the crew cab.

70% of pickups could use aluminum by 2025

In the next decade, the auto industry will see an explosion in its use of aluminum to cut weight and increase fuel economy, according to a study from market analysts Ducker Worldwide cited by The Detroit News. We are already seeing the lightweight metal show up extensively in luxury models from Europe, but with the impending launch of aluminum-intensive 2015 Ford F-150 (pictured above), North America is using it even more, as well. The report predicts 70 percent of US pickups to have aluminum bodies by 2025.
It won't just be pickups that see the benefit, though. The average amount of aluminum in US vehicles is forecasted by the study to grow from an average of 350 pounds in 2013 to about 550 pounds by 2025. The most common parts to use it will be hoods, doors and - to some extent - roofs, as well.
The massive increase in pickups' aluminum content hardly seems surprising. The F-150 is predicted to use so much that it might cause a short-term shortage, according to one earlier report. At the same time General Motors is heavily rumored to be negotiating with suppliers for the next generation Chevrolet Silverado and GMC Sierra. Ram is the last holdout of the Big Three, but the study predicts that not to last.

Child cobalt miners: Automakers pledge ethical minerals sourcing for EVs

BERLIN - Leading carmakers including Volkswagen and Toyota pledged on Wednesday to uphold ethical and socially responsible standards in their purchases of minerals for an expected boom in electric vehicle production. Demand for minerals such as cobalt, graphite and lithium is forecast to soar in the coming years as governments crack down on vehicle pollution and carmakers step up their investments in electric models. To cover its plans for more than 80 new models by 2025, Volkswagen alone is looking for partners in China, Europe and North America to provide battery cells and related technology worth more than 50 billion euros ($59 billion). Talks with major cobalt producers, including Glencore, at VW's Wolfsburg headquarters last week ended without a deal. More than half of the world's cobalt comes from the Democratic Republic of Congo, a country racked by political instability and legal opacity, and where child labor is used in mines. On Wednesday, a group of 10 leading passenger-car and truck manufacturers announced an initiative to jointly identify and address ethical, environmental, human and labor rights issues in raw materials sourcing. The partnership dubbed "Drive Sustainability" consists of VW, Toyota Motor Europe, Ford, Daimler, BMW, Honda, Jaguar Land Rover, Volvo Cars and truckmakers Scania and Volvo. The alliance "will assess the risks posed by the top raw materials (such as mica, cobalt, rubber and leather) in the automotive sector," said Stefan Crets of the CSR Europe business network. "This will allow Drive Sustainability to identify the most impactful activities to pursue" to address issues within the supply chain.Reporting by Andreas Cremer.Related Video: Image Credit: Michael Robinson Chavez/The Washington Post via Getty Images Green BMW Ford Honda Jaguar Land Rover Mercedes-Benz Automakers Toyota Volkswagen Volvo Green Automakers Green Culture Electric Scania ethics mining