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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).

Watch how a Ford Raptor rolls down the assembly line in Dearborn

Bloomberg TV reporter Matt Miller is the proud new owner of a pretty killer truck. How do we know? The reporter headed to Dearborn, MI to Ford's assembly plant, with a film crew in tow, to see exactly how his new F-150 SVT Raptor and its mother-loving 6.2-liter V8 engine, was screwed together.
The resulting video does an excellent job of summing up how an assemblage of parts and pieces is turned into a triple-black Raptor, thanks to the work of some 1,000 employees and about 20 hours of real time. Click through below to see how the truck is born, with a surprise cameo playing the part of delivery driver at the end.

Ford C-Max spied with fresh updates

The Ford C-Max hatchback looks to be getting a few cosmetic updates, as evidenced in this latest set of spy photos. Like the smaller Focus, which also received a nip/tuck for the 2015 model year, the C-Max appears to be getting a revised front fascia with slimmer headlamps and a more, shall we say, Aston Martin-like grille. Around back, there looks to be a new bumper with redesigned taillamps, as well.
In other markets, the C-Max people-mover is available with a range of powertrains, but here in the US, it exists either as a traditional gas-electric or plug-in hybrid. The C-Max's fuel economy has been a particular topic of interest lately, with its official fuel economy ratings having been lowered twice since the vehicle's launch. Sales initially suffered a bit following this fiasco, though numbers have since leveled out. It's unclear if Ford is working on any powertrain tweaks for the updated C-Max seen here, however.
Ford has likely spruced up the hatch's interior, as well, though we don't have photos of that at this time. Mum's the word on when we'll see the new C-Max, but our best guess is that it'll arrive sometime in the next year.