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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 profits soar as problems mount

Ford is doing well. It can't make enough examples of its new Fusion, it can barely make enough of the aging F-150, it's getting good brand rankings, people like its turnaround story, it's selling oodles of product and its quarterly profit numbers end in the word "billion." As other high-flying examples have demonstrated over the past few years, though, big numbers can come with problems that aren't exactly small.
Automotive News has published a good "nutshell" report of Ford's progress and problems. The Dearborn automaker's optimistic "general label rule" determination of gas mileage for the C-Max Hybrid has led to lawsuits, hybrid software updates, a downward revision of C-Max fuel economy and millions in rebates. AN notes the C-Max was the "worst-scoring model in this year's J.D. Power Initial Quality Study," but Ford will probably be happy that it managed not to be mentioned further in the study's results after last year's mediocre showing. Its MyTouch and SYNC systems, the bugbears sabotaging Ford's J.D. Power results, have also led to lawsuits, software updates, more software updates and a center console rethink. On top of that, the 1.6-liter EcoBoost in the 2013 Ford Escape that Ford called a "hero" was soon catching fire for three different reasons. And let's not even get into the troubled launch of the Lincoln MKZ.
The Automotive News piece notes that industry observers have been surprised at Ford's stumbles because everything has been looking so good. Nevertheless, there is still the issue of those billions in profits - the company is doing plenty of things, plural, right. Ford says it is tackling its problems, hiring engineers and instituting new quality control processes as part of its effort to find solutions. The test will be to see if in a year from now we begin the discussion of these issues with "Remember when Ford...", or "Problems continue at The Blue Oval."

This Ford F-150 might have a Land Rover turbodiesel V6

Our spy photographers just caught this Ford F-150 driving around Dearborn, wearing camouflage around the bed – not so unusual near Ford's headquarters. What's interesting with this particular mule is that it might be packing a Jaguar-Land Rover turbodiesel V6. As with the Super Duty, the F-150 prototype pictured here sports a Venturi exhaust tip popping out the side of the rear bumper behind the wheel, which – along with the sound reported by our shutterbug – suggests that it's burning oil up front. That could mean Ford has found another application for the 3.2-liter, five-cylinder Power Stroke diesel that it just federalized for the Transit van. However our sources suggest what the mule is actually powered by the 3.0-liter Lion V6 diesel that Jaguar Land Rover – once subsidiaries in Ford's Premier Automotive Group – is bringing over for the Td6 models of the Range Rover and Range Rover Sport. The engine produces a respectable 254 horsepower and a healthy 443 pound-feet of torque, and is tipped to be mated to the same ten-speed automatic transmission as the new Raptor. That could give the F-150 the kind of fuel economy and muscle it would need to challenge the likes of the Ram 1500 EcoDiesel and the heavier-duty Nissan Titan with the Cummins engine. With gas prices as low as they are, however, and sales of diesel-powered vehicles lagging, Ford could just be trying to keep up with the competition by offering a light-duty diesel pickup. With its lightweight aluminum body, the diesel F-150 could even surpass the Duramax diesel-powered Chevy Colorado and GMC Canyon for frugality at the pumps, according to Mark Williams of PickupTrucks.com. He told Autoblog that, "it makes perfect sense for Ford to do a diesel. It seems like everyone is pushing them to do a Ranger, but if they can get the F-150 to push 30 mpg it can challenge the Ram Ecodiesel and even the Colorado Duramax." Reached for comment, Ford spokesman Mike Levine sent us the following statement: "We do not speculate about future products. While diesel is a solution, it is not the solution. EcoBoost offers the ideal combination of performance and fuel economy that over 60 percent of F-150 customers are choosing." Featured Gallery 2017 Ford F-150 Diesel: Spy Shots Image Credit: Brian Williams / SpiedBilde Green Spy Photos Ford Land Rover Truck Diesel Vehicles jaguar land rover ford f-150 diesel