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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).

Next Ford Mustang to drop 400 pounds

The Ford Mustang is already the lightest of the current crop of muscle cars, at around 3,600 pounds for a GT coupe with the six-speed manual transmission. That's almost 260 pounds less than a Chevrolet Camaro SS and about 450 pounds less than a Dodge Challenger R/T, which means the Mustang has a pretty big advantage when it comes to handling, braking, accelerating and economy. More good news: The next Mustang will be even lighter.
According to a report from Edmunds, the sixth-generation Mustang, which is set to debut at the 2014 North American International Auto Show, will shed an additional 400 pounds of body fat. That 11-percent weight reduction will be thanks to lightweight materials, with a particular focus on using stronger, but less material in construction. Aluminum will feature heavily, but Edmunds' inside source warns that there is "nothing terribly exotic" coming to the original pony car.
The other big news is that the new Mustang will be smaller overall. It's going to be 15-inches shorter than the 188.5-inch Mustang on sale today, while it'll also be 6.5 inches narrower. Shorter overhangs, both in the front and rear, are also good signs for those that want an agile Mustang.