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Ford Gets The Aluminum F-150 Ready For Prime Time

Russell Barnett, a Ford dealer in Tennessee, is ready for aluminum. Ford is using the metal almost exclusively in body of the 2015 version of its best-selling F-150 pickup, which starts arriving at dealerships next month. Barnett is already answering customers' questions about the truck. And he's updated his repair shop not only for the F-150, but in anticipation that other Ford brands such as the Mustang will eventually make the switch from steel. But, just in case, he ordered some extra steel-bodied 2014 pickups. "There will be some people who won't want to change for a while," says Barnett, who says pickups make up around half of the annual sales at his dealership in rural Winchester. Ford is doubling down on aluminum, which is lighter - and more expensive - than steel but just as tough. The new truck is the company's response to customers' requests for a more fuel-efficient and nimbler pickup. Fordhopes the advantages outweigh customer doubts about the durability of aluminum or potential repair costs for the pricier metal. It's a big risk. So far this year, one out of every three vehicles Ford sold in the U.S. was an F-Series pickup. Morgan Stanley estimates F-Series trucks account for 90 percent of Ford's global automotive profit. On Tuesday, it kicked off production of the new truck at its Dearborn Truck Plant, four miles from the company's headquarters. "Yeah, this is a risk, but it's one well worth taking." said Bill Ford, the company's executive chairman, as he stood alongside the assembly line. "For our customer, this is a big, big leap forward." The trucks have been the best-selling vehicles in the U.S. for 32 straight years; last year, Ford sold nearly 100,000 more full-size pickups than General Motors. Aluminum isn't new to the auto industry, but this is the first time it will cover the entire body of such a high-volume vehicle. Ford made 647,697 F-150 pickups at its two U.S. plants last year; that's one every 49 seconds. If Ford's bet pays off, it could pad its lead in the lucrative truck market. More importantly, aluminum "future proofs" the truck - and the company - in an era of rising fuel economy standards, says Karl Brauer, a senior analyst with Kelley Blue Book. Ford will announce the truck's fuel economy figures later this month. That could determine if it steals customers away from the Silverado or Ram. Truck buyers are among the most loyal in the auto market.

2015 Ford F-150 to get up to 26 miles per gallon

The 2015 Ford F-150 is one of the most important US vehicle debuts in years, be it in the pickup segment or the entire marketplace. While we've already known about the truck's engine lineup, its payload ratings and we've even learned a bit about how it drives, the truck's EPA-estimated fuel economy ratings have remained a mystery. The wait is finally over. Ford has announced numbers that put the latest F-150 as the mileage leader among gasoline-powered, full-size pickups in the US, with its new 2.7-liter EcoBoost V6 topping the charts. Starting with the entry-level naturally aspirated 3.5-liter V6, the rear-wheel-drive F-150 is rated at 18-miles-per-gallon city, 25-mpg highway and 20-mpg combined. Opting for four-wheel drive drops those numbers slightly to 17/23/19. If fuel economy is your absolute priority, then upgrading to the 2.7-liter EcoBoost V6 is the hot ticket. It improves things further to 19/26/22 in rear-wheel drive trim or 18/23/20 with four-wheel drive. The carryover naturally aspirated 5.0-liter V8 is rated at 15/22/18 as a 4X2 or 15/21/17 as a 4X4. Finally, the flagship 3.5-liter EcoBoost V6 tops the range in available torque and offers buyers 17/24/20 ratings with rear-wheel drive or 17/23/19 with four-wheel drive. "We are delivering with the toughest, smartest and most capable F-150 ever – and now the highest EPA-estimated fuel economy ratings of any full-size gas-powered pickup in America," said Raj Nair, Ford group vice president, Global Product Development, in the company's announcement. Depending on engine and drivetrain configuration, Ford contends that the 2.7-liter EcoBoost's top rating puts fuel economy up between 5 and 29 percent over the current generation, thanks in large part to the truck's lighter aluminum construction. Obviously, these are EPA estimates, and your mileage may vary – ours has. Recently, Autoblog team members have had real difficulty even approximating government mpg estimates on many EcoBoost models, including the new F-150. Scroll down to read Ford's full announcement, including comparisons to rival models.

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).