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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).

Ford Recalls Nearly 700,000 Vehicles

Ford is recalling more than 692,000 Escape small SUVs and C-Max gas-electric hybrids in North America to fix two safety problems. The recalls cover vehicles from the 2013 and 2014 model years. Most of the Escapes have both problems. The first case covers 692,500 Escape and C-Max vehicles. A software glitch can stop the side curtain air bags from inflating in certain types of rollover crashes. The company says it has no reports of crashes or injuries. Dealers will reprogram the air bag control computer for free. About 65,000 of the recalled vehicles are C-Max models, and the rest are Escapes. Roughly 591,000 are in the U.S., with 3,500 more in U.S. territories. About 78,000 are in Canada and another 19,500 are in Mexico, Fordspokeswoman Kelli Felker said in an e-mail. There could be more vehicles affected in other markets, the company said. The affected Escapes were built from Oct. 5, 2011 through Feb. 14, 2014. The C-Max vehicles were built from Jan. 19, 2012, through Feb. 24, 2014. The second case covers about 692,700 Escapes. Exterior door handles can bind and stop the door from latching properly. This could allow doors to open while the SUVs are in motion. Dealers will inspect the handles and reposition them if needed. No crashes or injuries have been reported. About 583,000 are in the U.S. or its territories, with another 89,500 in Canada and 20,000 in Mexico. Ford said in this case, the problem may affect vehicles in other markets. All the North American Escapes were built from Oct. 5, 2011, through April 10, 2014. Recalls Ford escape

2015 Ford F-150 [w/videos]

To learn more about the all-new 2015 F-150 and get an early read on its potential hero-or-zero status, we flew to the heart of full-size pickup truck country, San Antonio, TX, to spend a day driving, towing and playing in the mud with an assortment of Ford's innovative new trucks.
First, a caveat - while we feel we have a reasonably good handle on the new F-150 after attending this first-drive event, we are far from ready to pass definitive judgment on the success of this radically new rig. Our time in the various models was lamentably limited and we felt rushed. With so much at stake and with so much to talk about and experience, we had zero alone time with the vehicle - there were Ford folks shadowing us at every moment.
And we still don't know everything there is to know about the trucks, as Ford is withholding some of its most crucial numbers, including curb weight data and anticipated EPA fuel economy figures. We don't even have a firm on-sale date. All of this information is typically disclosed - or at least officially estimated - at the time of a new vehicle's first drive. This limits the scope of the judgments we feel comfortable making based on our first encounter.