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Ford dealers offered discounts on tools to fix aluminum

With the introduction of the aluminum-bodied 2015 Ford F-150 (and the likely use of aluminum in future Ford products), Ford is looking to help its dealerships reduce costs related to repairing this more labor-intensive material. Automotive News is reporting that Ford dealers with body shops will require an estimated $30,000 to $50,000 in equipment and training to work on aluminum, and to help alleviate the financial burden of the new F-150, Ford has announced a special 20-percent discount on this equipment.
Dealers will be able to save up to $10,000 on tools such as welders, air-filtration systems and rivet guns and to create aluminum-specific work stations. The new F-150 goes on sale in the fourth quarter, and dealers have until October 31 to take advantage of this deal, according to the report.

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).

2013 Ford C-Max Hybrid recalled over lack of roof padding

Ford is recalling 33,021 units of its 2013 C-Max Hybrid not equipped with optional panoramic roof panels. During testing, the model in question returned testing results for occupant head injuries that fell outside of criteria laid out in the Federal Motor Vehicle Safety Standard. The issue puts occupants at greater risk of injury in the event of a crash if they are in an affected car.
The recall will begin August 19, at which time C-Max Hybrid owners can take their cars to dealers to have energy-absorbent material installed between the headliner and roof. The bulletin below from the National Highway Traffic Safety Administration has more information.