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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).

2015 Ford Mustang already under recall, but just 53 units

Ford has issued a small - but significant - recall for one of its spotlight cars: the 2015 Mustang.
The recall affects just 53 cars, with 50 in the United States and three in Canada. Ford said the passenger side safety belt buckle tension sensor may not have been calibrated properly by the supplier. This could lead to "misclassification" of the passenger seat occupant, and could cause the airbag to deploy improperly.
A Ford spokesperson didn't immediately respond to a request for comment. In a statement, the automaker said it is not aware of any accidents or injuries, and dealers will replace the buckle assembly at no cost to customers. The cars affected were built at Flat Rock Assembly Plant in Michigan from Aug. 18 to Oct. 2.

Ford's first PHEV in Europe could be C-Max

Ford could start selling a plug-in hybrid in Europe pretty soon, according to at least one of its executives. Whether it's willing to do so is another story. But if the market perks up, so will the company. The automaker can "quickly" develop a plug-in hybrid version of its Mondeo, the sister car to the Ford Fusion, Automotive News Europe says, citing Ford executive Uli Koesters. The subject of Ford selling plug-in hybrids in Europe is more vital than ever since Volkswagen recently started selling its first PHEV (a Golf) there. VW will also debut a Passat PHEV next year. Koesters was less certain about whether there was sufficient European demand to warrant a production PHEV from Ford. Europe's biggest-selling plug-in hybrid through the first half of the year was the Mitsubishi Outlander PHEV. That model, according to JATO Dynamics, moved almost 9,000 units through June. Toyota sold almost 4,300 Prius Plug-in Hybrids in Europe during that time period. And we can't be sure Ford's first European PHEV will be the Modeo/Fusion, either. In fact, Ford's first plug-in hybrid for Europe is more likely to be the C-Max, John Gardiner, a Ford spokesman in Europe, told AutoblogGreen. He would only say that it would be sold "in selected markets soon," without being more specific. Ford's two PHEVs in the US have been selling well this year. Through September, sales of the Fusion Energi PHEV almost tripled to 9,323 units, while Ford C-Max Energi PHEV sales were up 51 percent to 6,486 units.