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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).

Weekly Recap: Audi pulls back the curtain on its future

The E-Tron Quattro concept is the future of Audi. It embodies all of the traits that will make the brand – and electric-powered luxury vehicles – more relevant into the 2020s. Here's why: The E-Tron Quattro concept, which will debut next month at the Frankfurt Motor Show, is a large sport utility vehicle that promises a range of 311 miles. It's an all-electric daily driver that fits the needs of most Americans. In production – which Audi says starts in 2018 – this vehicle will seat five and likely be called the Q6. You can take your family from Boston to Philadelphia without recharging. That's mainstream. We're moving away from the industry's "science experiment" era (as General Motors product chief Mark Reuss once described the appearance of the first gen-Chevy Volt) to a period where electric vehicles are plausible and practical for many US buyers. The 2018 Q6's only holdup for the masses will be price. But if you can afford an Audi SUV, you'll be able to buy an all-electric version. The E-Tron concept uses Volkswagen Group's second-generation modular longitudinal platform. The lithium-ion battery is located between the axles and below the cabin. Urquhart says the production model will feature the automaker's latest battery technology developed with LG Chem and Samsung. IHS Automotive projects the Q6 will sell more than 40,000 units annually by the end of the decade. "The E-Tron Quattro is a precursor for what will be an exciting and landmark production model for Audi and will position the brand at the forefront of the premium EV market," IHS analyst Tim Urquhart wrote in a commentary. It's the Tesla-zation of America. It's the Tesla-zation of America. The Q6 will be a Model X fighter, and expect other automakers to follow suit, particularly in the luxury sector with SUVs and other large vehicles. They offer more space for the battery packs, and development costs can be recovered easier. "Premium brands have an inbuilt advantage in terms of introducing [electric] powertrains over more mainstream automotive brands," Urquhart wrote. OTHER NEWS & NOTES Analyst says Tesla stock could be worth $465 a share Morgan Stanley analyst Adam Jonas sent shockwaves through the industry when he said Tesla stock has the potential to reach a whopping $465 a share. That's a leap from its $230.77 price at Friday's market close.

Ford recalling 390,000 cars over door latch woes

Ford is recalling certain Fiesta, Fusion and Lincoln MKZ vehicles due to faulty door latches, marking the latest in what seems to be a recurring issue for the Blue Oval. This is the third door latch recall from Ford in 2015, following a 213,000-unit recall in March and a 205,000-unit recall in January. This one, however, is significantly larger. A total of 390,000 units are affected, including Fusions and MKZs from model years 2013 and 2014, as well as Fiestas from model years 2012 to 2014. A "broken pawl spring tab" is the culprit, potentially keeping doors from latching shut. According to Ford, even if the door does shut, it could come open again without warning. The affected Fiestas were built between February 1, 2012 and May 31, 2013 at the Cuautitlan, Mexico factory. The Fusion and MKZ siblings, meanwhile, were screwed together at Hermosillo Assembly in Mexico between July 1, 2012 to May 31, 2013. Ford is aware of three minor reports of door malfunctions. In two cases, the door bounced back open, quite literally hitting drivers on their way out. In the third case, a door swung open of its own accord while a driver was attempting to park, hitting another vehicle. Ford will notify owners, who will need to report into dealers to have all four latches replaced. Scroll down for the official press release. Related Video: APR 24, 2015 | DEARBORN, MICH. FORD MOTOR COMPANY ISSUES SAFETY RECALL IN NORTH AMERICA FOR DOOR LATCH ISSUE ON FORD FIESTA AND FUSION, LINCOLN MKZ Ford Motor Company is issuing a safety recall for approximately 390,000 2012-2014 Ford Fiesta and 2013-2014 Ford Fusion and Lincoln MKZ vehicles for a door latch issue. The door latch in these vehicles may experience a broken pawl spring tab, which typically results in a condition where the door will not latch. If a customer is then able to latch the door, there is potential the door may unlatch while driving, increasing the risk of injury. Ford is aware of two allegations of soreness resulting from an unlatched door bouncing back when the customer attempted to close it, and one accident allegation when an unlatched door swung open and struck an adjacent vehicle as the driver was pulling into a parking space. Affected vehicles include certain 2012-2014 Ford Fiesta vehicles built at Cuautitlan Assembly Plant, Feb.