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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).

GM being sued over imploding Bosch fuel pumps in Duramax diesel trucks

Texas-based law firm Hilliard Martinez Gonzalez (HMG) this week filed a class-action lawsuit against General Motors over an alleged issue with Bosch CP4 fuel pumps. The suit claims Bosch designed the CP4 pump to work with European diesel fuel, which is thicker than U.S. diesel. When GM installed that pump in the 6.6-liter Duramax engine used from the 2011 to 2016 model years, the lawsuit claims the thinner U.S. fuel didn't provide enough lubrication, allowing air pockets to form in the fuel pump. That, in turn, allegedly let metal rub against metal inside the pump, causing the pump to eventually disintegrate and "send thousands of metal shards into the fuel injection system and every part of the engine." The Detroit News reported on the most recent lawsuit filed in Michigan's Eastern District Court, but the case is another piece of nationwide legal maneuvering going on since at least last September. Every U.S. truck maker used the Bosch CP4 fuel pump, and HMG originally went after all of them, as well as Bosch. On September 30, 2018, HMG filed a class-action suit in Texas on behalf of eight plaintiffs. The law firm wanted to prosecute the affair under RICO — the Racketeer Influenced and Corrupt Organizations Act — and named 10 defendants: FCA US LLC, FCA North America Holdings, LLC, F/K/A Chrysler Group, Fiat Chrysler Automobiles, N.V., Ford Motor Company, General Motors LLC, Robert Bosch GmbH, Robert Bosch LLC, VM North America, Inc., and VM Motori S.P.A.  The firm filed another suit in Florida on Nov. 2, 2018, against the same 10 defendants, again under the RICO statute, this time on behalf of more than 30 plaintiffs. We don't know how many other suits might have been filed, but the two suits mentioned apparently didn't have legs — the courts dismissed both quickly. So HMG shifted its strategy away from the RICO angle, and focused its efforts on GM, filing suit in California on Nov. 20, 2018. Instead of trying to catch 10 fish with a small net, HMG wants to score one fish with a big net. The results have borne more promise for the plaintiffs. In July this year, a judge in California denied GM's motion to dismiss, noting "the alleged defect is central to the vehicleÂ’s function." This latest suit filed on Aug. 6 in Detroit singles out GM again.  The Bosch CP4 is known to be problematic, however.

Ford Australia reveals updated Territory, Falcon via Twitter

Ford may have tied together much of its global lineup under the One Ford campaign, but one market where it still offers unique products is Australia. That will soon draw to a close as well, but before it does, the Blue Oval's Aussie operations are rolling out refreshed versions of its two unique products. For the moment, Ford isn't revealing much in the way of powertrain details, but it has shown off a couple of snaps of the revised products on its in-market Twitter feed.
First up is the new Territory. The SUV is neither based on a front-drive crossover platform nor on a truck frame, but shares its rear-drive underpinnings with the Falcon, taking it a step beyond the Falcon wagon alongside which it sits in Ford's Aussie range. Like the outgoing third-generation SZ Territory, the facelifted version is dominated by a narrow grille and larger front air dam, but further punctuates its big-chinned look with more rugged lower cladding and other metallic inserts that bring its look up to date.
And there's the Falcon, which Ford revealed in XR8 trim just last week and is now presenting in G6E spec. If the XR8 is the performance model, the G6E is the luxury version, swapping in more refined trim like a chrome-slat grille (instead of a black honeycomb), chrome foglamp surrounds, less-aggressive multi-spoke wheels (instead of five-spokes) and a flatter hood (instead of a power bulge). Otherwise, it looks essentially the same as the one we saw last week, its facelift bringing it more in line with the smaller, front-drive Mondeo (which we know here as the Fusion) and other members of the Ford family.