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GM readying aluminum-body fullsize pickups

Ford's extensive use of aluminum in its 2015 F-150 is a big deal. A really big deal. Big enough, in fact, that General Motors is reportedly changing its fullsize pickup strategy. According to The Wall Street Journal, The General has locked in partnerships with Alcoa Inc. and Novelis Inc. - companies that will supply aluminum for the next-generation Chevrolet Silverado and GMC Sierra trucks.
"Ford's introduction of the 2015 F-150 pickup truck was a game changer, and it's the first, not the last, conversion of this type," Novelis spokesperson Charles Belbin told the Journal. The switch to aluminum has allowed Ford to shave roughly 700 pounds off its fullsize truck's curb weight. And while official mileage ratings have not been announced, the weight loss should go a long way for improving efficiency, especially when combined other efficiency-minded improvements including better aerodynamics and new, turbocharged V6 engines.
Of course, aluminum-bodied cars are nothing new. But extensive use of aluminum in a major, best-selling product like the Ford F-150 is expected to kick off widespread use of this weight-saving material as availability rises and cost decreases. The WSJ reports that GM had originally explored the idea of moving to aluminum pickups back in 2008, but abandoned the idea due to cost concerns amid economic woes.

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).

Will the new Ford GT race at Le Mans?

Ford stole the spotlight here on the floor of the Detroit Auto Show this year with the reveal of the new GT. Its carbon-fiber chassis, 600-plus-horsepower EcoBoost engine and radical aerodynamic shape made sure of that, but flanking it with the debuts of the Mustang GT350R and F-150 Raptor didn't hurt any, either. Any racing fan looking at the new Blue Oval supercar, however, had to wonder whether Dearborn is planning on putting it on the race track. The House that Hank Built is, after all, a known entity in motor racing. It may be canceling its V8 Supercars program Down Under, withdrawn its support from the World Rally Championship, and it's been years since it's competed in Formula One or Indy. But it still competes in the United SportsCar Championship, NASCAR, NHRA and a variety of motor racing disciplines. One of its most famous and celebrated of racing endeavors, however, came in the form of the original GT40 that brought Ford four consecutive victories at the 24 Hours of Le Mans, starting with a dominant one-two-three finish in 1966. It's the 50th anniversary of that landmark win which the new Ford GT celebrates, but while the press materials made clear reference to that historical event, any mention of a return as was previously speculated was carefully omitted. That, according to Autosport, could come down purely to the ACO, the organizers of the event and sanctioning body for its associated series, which has yet to announce the revised format for the GTE class under which a potential Ford GT racer would compete in 2016. Longtime Ford racing partner Multimatic is said to have closely consulted with the ACO on the formation of those rules, however, and assuming they're finally formulated to Dearborn's liking, we could be looking at a GTE-spec Ford GT to return to La Sarthe next year in celebration of that landmark victory half a century prior. Chip Ganassi Racing – which races under Chevy power in NASCAR and Indy but recently switched to Ford for its Daytona Prototype – is said to be in line to field the car on Dearborn's behalf. If given the green light, it would be the first time Ford would field a factory effort at Le Mans since the C100 project under the Group C category in the early 1980s. A racing version of the previous Ford GT was prepared by Switzerland-based Matech a few years ago, but without factory support or notable success beyond the FIA GT3 European Championship.