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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.

Diesel details: Comparing Ram 1500 EcoDiesel, Chevy Silverado Duramax, Ford F-150 Powerstroke

With specifications for the 2019 Ford F-150 Power Stroke diesel already out, and the details on the 2020 Ram 1500 EcoDiesel and Chevy Silverado Duramax (and its GMC Sierra twin) trickling out, we felt it was a good time to start comparing the full-size trucks' light-duty diesels. Bear in mind, we've only driven one of these new diesel trucks, so we'll be sticking to numbers for now. Some numbers haven't been announced yet, either, but stay tuned, because we'll be updating this post with additional specifications as they become available. And if you want to compare any other versions of these trucks with other vehicles, be sure to check out our comparison tool. Now let's start comparing, starting with our big chart of numbers below. As we can plainly see, these trucks are quite closely matched. Each one has six cylinders, a displacement of 3.0 liters and a turbocharger to boost it. The output of each is somewhat close, too. The Ram 1500 EcoDiesel is the torque king at 480 pound-feet, 20 more than the GM trucks and 40 more than the Ford. The GM trucks win on power, though, with 277 ponies, 17 more than the Ram, and 27 more than the Ford. GM does report that you get their trucks' peak 460 pound-feet of torque from 1,500 rpm to 3,000 rpm, whereas the others only report peak torque at a particular point in the rev band, but all of these trucks should have wide, flat torque curves as you would expect from modern turbodiesels. 2020 Ram 1500 EcoDiesel View 8 Photos Engine output is only one part of the truck performance equation. We also have towing and payload capacity, as well as fuel economy. With towing, the Ram 1500 is the current leader with a maximum capacity of 12,560 pounds. That tops the Ford F-150's 11,400-pound tow rating by well over 1,000 pounds. The F-150 can carry 2,020 pounds in its bed, but we don't know yet whether that's better or worse than the Ram or the GM trucks. We also don't have numbers for the GM trucks' towing capacities. View 9 Photos As for fuel economy, the Ford F-150 manages a thoroughly impressive 22 mpg in the city and 30 on the highway with two-wheel drive. Choosing four-wheel drive drops those numbers to 20 and 25 respectively. The fuel economy numbers for the Ram, Chevy and GMC haven't been revealed yet, but for some comparison, we can look at the old Ram EcoDiesel. That truck's best fuel economy was 20 in the city and 27 on the highway with two-wheel drive.

2015 F-150 launch to curb Ford profits?

Ford is making a big bet on aluminum with its new 2015 F-150, and it's possible that the decision will hurt the company financially, at least in the short term. After earning a record $8.6 billion in 2013, the Blue Oval does not expect to set another record in 2014. According to Automotive News, that's "largely attributable to F Series," says Bob Shanks, Ford's Chief Financial Officer.
To retool for the new F-150, Ford will idle its Dearborn Truck Plant in Michigan for 11 weeks and the Ford Kansas City Assembly Plant in Missouri for 2 weeks. "3 of the 13 overall weeks occur during what normally is our summer shutdown timeframe," said Mike Levine, Ford Trucks Communication Manager, in an email to Autoblog. The extra 10 weeks will be preparing for the more aluminum-intensive construction for the trucks and will mean over 2 months of no F-150s being made. For comparison's sake, Chrysler boss Sergio Marchionne just confirmed that the 200 plant in Sterling Heights, MI will be down for 30 days to retool for the new model, but obviously there are many more F-150 production variables than for the midsize sedan.
Levine notes that Ford is already running three shifts at both plants, and says the automaker has plans to ensure that there is adequate supply of the full-size pickups during the retooling process. The company does not want to suffer a shortage of the vehicle that accounted for 31-percent of its 2013 US sales and an even bigger percentage of its profits.