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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).

Man has surgery to remove T-Bird turn signal that's been in his arm for 51 years

In 1963, real estate agent Arthur Lampitt was driving a new Ford Thunderbird near East Peoria, Illinois on his way to an appointment when he collided head-on with a truck. A massive accident that was so bad that it was originally reported as a fatal crash, Lampitt suffered a broken hip and that became the focus of doctors' efforts. In fact, no one noticed the fact that the turn-signal stalk had been broken off the steering column and had lodged itself in Lampitt's arm. Fast-forward to around ten years ago, when Lampitt set off a courthouse metal detector because of a "slender object, about the size of a pencil" in his arm. Despite that unnerving discovery, the doctor who examined Lampitt said that since it didn't hurt, he needn't worry about it. This year, however, it did start hurting and the affected arm started to bulge. Lampitt decided to have the issue seen to, and suspected it might have something to do with his 1963 accident. When he looked through photos of the wreck taken by a friend, he noticed the turn-signal stalk of the Thunderbird missing and figured that was the culprit. After a 45-minute outpatient surgery, the surgeon verified it: a slim, slightly bent and corroded, seven-inch metal cylinder with a trumpeted end. The surgeon said a protective pocket had formed around it, which is why it could remain in Lampitt's arm so long, but it was still unusual - "We see all kinds of foreign objects like nails or pellets, but usually not this large." Lampitt, who is expected to make a full recovery, says he might make a keychain out of it, once he's done just holding it. News Source: St. Louis Post-DispatchImage Credit: Jesse Bogan, St. Louis Post-DispatchTip: Jon Auto News Ford Coupe accident wreck ford thunderbird turn signal

J Mays' legacy

Mays is by far not the first designer to use heritage design cues in his work.
The announcement that J Mays will be leaving his chief creative officer role at Ford Motor Company on January 1 ends a 13-year run in one of the industry's top design roles. While best known for having a hand in reborn classics like the Volkswagen New Beetle, Ford Mustang and Thunderbird (above), Mays' legacy is more complicated and nuanced than being considered the father of what is known as "retrofuturism".