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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 lowers MPG ratings on six vehicles

Ford has announced that it will be lowering the fuel economy ratings on a number of its 2013 and 2014 model year vehicles after an error was discovered in the company's internal testing data. The EPA has been notified.
Worryingly for Ford, the vast majority of the vehicles affected are hybrids, including the C-Max, Fusion and MKZ in both hybrid and plug-in varieties (where applicable). Also covered as part of the rerating is the entire lineup of 2014 Fiesta engines, with the exception of the ST, including the turbocharged, three-cylinder EcoBoost.
The C-Max was originally rated at 47/47/47 mpg, but dropped to 43/45/40 last year and now to 40/42/37.

Ford also opening up EV, hybrid patents, with a price tag

Like Tesla and Toyota before it, Ford is seeing the light when it comes to freeing up alternative powertrain patents. Of course, the Blue Oval does things differently, so free doesn't mean no cost. Instead of making its electric vehicle patents simply available to anyone, Ford is going to sell off its EV tech for an unspecified fee. Ford says it has 650 electrified vehicle patents and another 1,000 or so pending EV tech patent applications. Ford filed 400 such applications last year alone. To buy these patents, interested parties should contact Ford's technology commercialization and licensing office or work AutoHarvest. Or, you know, you could just go get Tesla patents for free. The jury is still out on whether these open patent programs are being used. The Tesla program, for example, didn't seem to be all that exciting to most OEMs right after it was announced. Ford has six vehicles with some sort of electrified powertrain: the Focus Electric, Fusion Hybrid and Energi PHEV, Ford C-MAX Hybrid and Energi plug-in hybrid and the Lincoln MKZ Hybrid. The only full EV in that group, the Focus Electric, starts at $29,995. Ford Opens Portfolio of Patented Technologies to Competitors to Accelerate Industry-Wide Electrified Vehicle Development Ford is opening its portfolio of electrified vehicle technology patents to competitive automakers to accelerate industry-wide research and development of electrified vehicles In 2014, Ford filed for 400-plus electrified vehicle patents – more than 20 percent of the total patents the company applied for last year Ford is set to hire an additional 200 electrified vehicle engineers this year as the team moves into a newly dedicated facility – Ford Engineering Laboratories – home to Henry Ford's first laboratories DEARBORN, Mich., May 28, 2015 – Ford Motor Company is offering competitors access to its electrified vehicle technology patents – a move to help accelerate industry-wide research and development of electrified vehicles. In 2014, Ford filed more than 400 patents dedicated to electrified vehicle technologies. This is more than 20 percent of the patents the company filed – totaling more than 2,000 applications. "Innovation is our goal," said Kevin Layden, director, Ford Electrification Programs. "The way to provide the best technology is through constant development and progress.