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2015 Ford F-150 enters production

Ford has given the F-150 a dramatic makeover for 2015, switching to an aluminum body that helps reduce weight by about 700 pounds. Because the truck is dramatically different, Ford also had to change the way it makes the F-150, so we went inside its sprawling factory in Dearborn, MI, this week to see the Blue Oval's new manufacturing techniques in action.
The company has added 850 jobs at the site and upgraded its stamping and tool and die facilities. The body shop is also modernized, and it has been fitted with 500 new robots that join the structures together. The first 2015 F-150 rolled off the line on Tuesday, and the trucks will begin arriving in dealerships in December. Get a closer look at the F-150's unique assembly process in our video.

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).

Ford Escort Concept goes back to basics

Here's the thing about China: The folks buying cars there have a very different set of standards than shoppers in many other markets around the globe. While we all drool over hot metal with bold designs, and while we appreciate automakers going an extra step to inject even their cheapest offerings with aggressive and interesting cues, that sort of sheetmetal sex appeal doesn't always sell in the People's Republic. Case in point is Jaguar, which may be designing a more traditional-looking version of its XJ for the Chinese market, or more to the point of this story, Ford currently sells the less-exciting, last-generation Focus compact in China right alongside the new one.
So consider this new Shanghai-bound C-segment concept a preview of what's to come for that more traditional, budget-minded, less-sexy market. More proof of this pudding: Ford's even calling this concept the Escort - a nod to the Blue Oval's compact car days of yore, and a name that stirs up thoughts of basic, affordable transportation rather than great driving dynamics or bold design. "Customers in China described seeking a vehicle that is stylish - but not one that is arrogant or pretentious," Ford states. And this new Escort concept previews a possibility of providing exactly that for this rapidly expanding automotive market.
What you're looking at, then, is one of the most simple Ford designs we've seen of late, though it still incorporates all of the automaker's latest DNA. The signature hexagonal grille is front and center, flanked by attractive LED headlamps and chrome-rimmed foglamp housings. The entire car's design focuses on clean, smooth surfaces, with one strong character line flowing from front to back just below the beltline. We will say that the car looks decidedly more premium from the rear view, where narrow, horizontal taillamps with an LED accent give the car added visual width. Bland as it may be, it's a handsome little concept, though fear what would likely happen if all of the conceptual details get dumbed down for a production model.