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Ford director says company has big efficiency plans, but no dedicated EV

The annual autofest known as the North American International Auto Show previews a plethora of exciting new products that we'll see and drive later in the year, from tiny urban commuters to family sedans and crossovers to hard-working big pickups and SUVs. It's also a once-a-year cornucopia of auto executives and leaders from around the world. "There will be some really fun stuff that you'll hear about in the future" - Ford's Kevin Layden So, in-between dozens of cool new-product unveilings on rotating stages during the two press days preceding the public show, we auto scribes grab what planned and impromptu interviews we can. Sessions with top industry leaders can be hard to get, but I was able to score a seat in a group session with then-General Motors North America president (now executive VP of global product development) Mark Reuss, and I also managed brief one-on-ones with a trio of vehicle electrification leaders, one each from Ford, BMW and GM, and what they said then remains relevant now. First up is Kevin Layden, Ford's Director of Electrified Powertrain Engineering. ABG: Where will Ford go beyond its current Focus EV and hybrids, and will there be a Ford EV and/or hybrid on its own energy-optimized platform one day. KL: We don't want to do a dedicated electric vehicle with all the development costs borne by a niche product. At the Michigan Assembly plant right now we're building the Focus electric, PHEV and EcoBoost on the same assembly line. Also the C-Max, with both a hybrid and an Energi plug-in, and we use that same power pack in the Fusion Hybrid and Energi. We want to be, "The power of choice" [a Ford marketing slogan], so having that choice for customers is very important. And if I want to sell the Fusion, Focus and C-Max globally, we can use these power packs wherever it makes sense. So as we go forward, you'll see us proliferating the power packs we have today. Then the question is, what do we do next? There will be some really fun stuff that you'll hear about in the future. ABG: Is the efficiency difference between a dedicated ultra-efficient vehicle platform and a shared multi-use platform getting smaller as all platforms get more efficient? KL: Exactly. Were going through aero studies now on wheels and tires and hood sealers on base vehicles. We have full aerodynamic wind tunnel studies going on with the base Focus and C-Max, so all of that [aerodynamic improvement] will be there for EVs.

Ken Block ain't got a care about ruining his wheels

During a drifting session at Irwindale Speedway in California, Ken Block made a boo-boo that would send a number of drivers immediately back to the infield. But there's an answer to "What do you do when you bash the wall while drifting and your wheel explodes?" and there's completely different answer when the question begins with the phrase, "When you're Ken Block..."
Instead of us telling you how Block handled the calamity in his Ford Fiesta competition car, you can watch it happen in the video below. You can probably also guess what it is - but it's more fun to watch.

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).