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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 F-150, Toyota Tacoma top ASG list of most eco-friendly trucks

No one's going to confuse the massively popular Ford F-150 pickup truck with a green vehicle, but at least it performs well in an environmental sense when compared to its brethren. The Automotive Science Group (ASG) took on the odd (to us, at least) task of measuring which pickup trucks are friendliest to the environment and found that the big seller in the Blue Oval's flagship F-series came up big, while the Toyota Tacoma came up, well, slightly smaller. That's a good thing. Among the 245 light-duty trucks that ASG studied, the 3.7-liter V6-powered F-150 won ASG's award for full-size trucks for both regular and crew cabs. Meanwhile, the 2.7-liter Toyota Tacoma, with its fuel-economy rating of 23 miles per gallon combined, had smallest overall life-cycle carbon footprint and won ASG's two mid-sized categories. Finally, the Chevrolet Silverado won best all-around performance in the full-size extended-cab category. The ASG factored in eco-friendliness, price and social performance (which is measured by, "considering the rights of those charged with vehicle manufacture and assembly") to come up with its findings. Sales of Ford's F-Series trucks rose 8.4 percent last year to 74,592 units and accounted for more than a third of the total 2013 sales of Ford and its Lincoln unit. Check out the ASG's press release below. Truck Buyers Faced With "Eco" Options Galore Which 2014 full-size trucks warrant eco claims? 25 March 2014 [Santa Rosa, CA] – With a myriad of eco-branded trucks hitting the North American marketplace in 2014 – from Ford's EcoBoost and GM's EcoTec3 to Ram's latest addition, the EcoDiesel – the Automotive Science Group (ASG) was prompted to offer an objective, scientifically-based assessment to determine exactly which 2014 trucks actually earn their "eco" badge. According to ASG and the principles of ecological economics, a vehicle's eco-rating must be multi-faceted to include both environmental and economic considerations, and so the Group's proprietary rating platform – the Automotive Performance Index – does just that. Using a unique combination of vehicle data inputs that include conventional specifications as well as social, environmental and economic performance indicators, ASG's vehicle assessments empower consumers to make choices based on one's personal principles and financial requisites.

How Ford secretly used customers to test its aluminum F-150 [w/video]

Automakers getting clever about disguising development vehicles isn't anything new. Between mules wearing the sheetmetal of other cars and prototypes decked out in as much camouflage as is practical, automakers know how to make it very difficult for the general public to get an exact idea of what kind of vehicle is in development. Ford, though, is rapidly becoming the master.
We knew that the Blue Oval originally tested the durability of the aluminum construction being used for the 2015 F-150 by building an all-aluminum 2014 truck and entering it in the Baja 1000 off-road race. That's no longer a secret. What we didn't know, though, is that the aluminum development dates back to before even that, and that some of the people in question had no idea what it was they were working with.
Ford says this is the first time prototypes have ever been handed over to the public.