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So far andre has created 252 blog entries.
13 06, 2014

Experts Foresee 70% Of Truck Market To Turn To Aluminum

2017-01-26T23:37:29+00:00June 13th, 2014|

The 2015 Ford F-150 isn’t even on sale yet but its impact is being felt around the automotive industry. It’s ground zero for an aluminum-based revolution, one that industry insiders see as picking up so much steam that every leading car manufacturer has an program for aluminum in place. In total, the industry experts at Ducker Worldwide foresee seven out of every ten trucks to have aluminum bodies by within a decade. From the Pittsburgh Business Times:

In the next decade, vehicles with complete aluminum body structures will reach 18 percent of North American production, up drastically from less than 1 percent today, and the number will be much higher for pickup trucks, according to a new report from Ducker Worldwide LLC.

Surveying automakers, the researchers found that every leading automaker will have an aluminum body program in place, with Ford, General Motors and Fiat Chrysler set to be the biggest users of aluminum sheet.

Within a decade, seven out of ten of all new pickup trucks sold in North America will be aluminum-bodied, according to the Ducker report.

Total North American light vehicle aluminum consumption will increase by 28 percent in 2015 over 2012. Aluminum sheet for light vehicle body and closure parts will grow from less than 200 million pounds in 2012 to nearly 4 billion pounds by 2025, according to the report.

As light vehicle aluminum content will approach 35 billion pounds globally, light vehicles are poised to be the most important global market for aluminum.

We’ll have to see how the F-150 does when it goes on sale this fall but with glowing early reviews and a shifting marketplace, there’s little doubt that its release will mark a true paradigm shift in the market. Stay tuned.

5 06, 2014

How Ford Made Aluminum Stronger Than Steel

2017-01-26T23:37:29+00:00June 5th, 2014|

Can aluminum truly be stronger than steel? Not just over the course of a truck’s life cycle, but through all of the immediate dings, dents, and rigor that a pickup truck needs to go through as it works from job to job?

Ford knew that these would be major questions going into the aluminum-based F-150.  Chief Engineer Pete Reyes came loaded with research and answers when it came time to face these types of questions and more…and as it turns out, the biggest problem with aluminum isn’t a material property. It’s perception. From Forbes:

The majority of the truck body is 6,000-series alloy aluminum, which is a heat-treatable alloy aluminum. Depending on the mix that you put in the alloy, but certainly more a function of how long you heat-treat it, you can get all manner of properties out of this aluminum. Some of our structural elements and our extruded pieces are heat-treated, and we end up with stronger pieces than the steel we’re replacing.

… You can just choose to heat-treat it to a strength and replace a steel part that just happened to not be as strong. But you can also just add gauge

[i.e. make it thicker]. Aluminum being a third as dense as steel, you can have three times the thickness before you have the same weight as steel. So in a lot of cases, we tailored it to the strength we needed.

People are asking, “How do you have more dent and ding resistance?” Well, aluminum actually has better properties for dent and ding resistance, but we can also just up-guage it another tenth of a millimeter and still save 40 percent of the weight.

Reyes has plenty more to say regarding the expectations of the truck and the engineering that went into, so be sure to check out the full article.

29 05, 2014

Where Can We Find Pure Aluminum?

2017-01-26T23:37:29+00:00May 29th, 2014|

We often discuss aluminum in the manufacturing process on this blog, whether that process is for something as big Ford’s flagship pick-up truck or the latest smartphone from Samsung or Apple. But what about out in nature?

While aluminum is a natural element usually found in the earth’s crust, it’s a very reactive elemnt and is usually found as a compound (combined with other minerals). So can pure aluminum actually be found? From American Minerologist via i09:

Several papers reporting exotic native elements have been published within the last few decades. The “native” occurrences described are rather dubious in view of the lack of solid proof of their relationships with the host-rock minerals. Consequently, the genetic models proposed ranging from bio-reduction to the influence of deep-mantle, strongly reduced fluids, are somewhat speculative. Here we present data for a unique Al0 flake protruding from the phlogopite matrix of a rock specimen collected from a desilicated pegmatite vein. The geologic setting suggests two processes that might have played a key role in the Al0 formation: (1) desilication of pegmatite, resulting in its Al residual enrichment; and (2) serpentinization of an ultramafic body, providing a strongly reduced front (H2 and hydrocarbons) toward the serpentinite/pegmatite contact. These processes have presumably led to the reduction of Al to Al0 at discrete sites of alumina-rich minerals.

If you understand what that means, then you’re a better scientist than we are. But for the laymen that just like to work with aluminum as a material, here’s the short version: the answer is yes, but only in extremely rare circumstances.

22 05, 2014

Make Aluminum Sculptures At The Fine Line Arts Festival

2017-01-26T23:37:29+00:00May 22nd, 2014|

Have you ever wanted to make cool things out of molten aluminum?

Okay, that sounds like an odd question, and chances are, you’ve probably never even thought of that situation. So let’s re-phrase that: given the opportunity, would you like to make cool things out of molten aluminum?

If the answer is yes, then you might want to fly out to Chicago in early June. At the Fine Line Arts Festival on June 6, you’ll be able to partake in the festival’s first aluminum sand casting event. From the Chicago Tribune:

Fine Line’s first aluminum sand casting event starts things off on Friday evening. Opening Night includes a catered dinner from BBQ on Wheels and live music performed by “Fight With Monsters.” Tickets are required for Opening Night only, and can be purchased online: fineline.org/fine-line-arts-festival, or in person at Fine Line.

Artist and Fine Line blacksmithing instructor Dan Caldwell, will be leading the aluminum pour. “We’re going to take a molding sand mixture, put tile forms on a board, and pack the sand around them,” he said. “After the pour, the mold is destroyed and (participants) will get to take the parts out, clean them off, apply a patina, and buff and polish their pieces.”

Those who attend Friday night will get to watch while the melted aluminum is poured into the molds, and will take their own finished pieces home that evening.

The festival also includes pottery making, copper etching, basket making, and other craft-related activities. However, we get the feeling that nothing will quite beat out playing with molten aluminum!

16 05, 2014

The World’s Most Stylish Aluminum House

2015-06-18T15:33:05+00:00May 16th, 2014|

Japan offers us plenty of technological innovations. At the same time, some of the quirkiest stuff in the world comes from Japan. This next aluminum-centric find is a little bit of both. Noted Japanese architect Terunobu Fujimori is known for his unusual and eccentric designs, and his latest design moves the single-home residence in a radical new metallic direction. From Archdaily:

Terunobu Fujimori’s Soft-Hard Aluminum House Opens Near Tokyo

A new private house designed by an exceptional Japanese architect, Terunobu Fujimori, has opened. The new building is located in a small provincial town near to Tokyo. Neighbored by typical one-family residences, the newcomer comes to the fore. Different, shiny and apparently soft metallic façade catches the visitor’s eye.

Yet the scale of the building is much smaller than one might expect. Every height, width and depth are accurately measured and left from a certain point of view spatially stingy: no waste is admissible here.

It’s difficult to fully describe the house in just a snippet. Do yourself a favor and go check out the full post at Archdaily’s site for photos and more information.

14 05, 2014

Report: The Dodge Ram Goes Aluminum

2017-01-26T23:37:29+00:00May 14th, 2014|

Get ready for more big American trucks made out of aluminum bodies. As we noted last week, auto manufacturers are sharing industry secrets about how to best use aluminum in a collective effort to lower the cost of materials and building. Chrysler (AKA the newly renamed Fiat Chrysler) has just thrown its hat into the ring with the popular Dodge Ram truck. From USA Today:

Fiat Chrysler, the new name for the combined Fiat and Chrysler Group, says it will redesign the popular Ram standard-duty pickup in 2017 and overhaul the heavy-duty line of pickups the following year.

And the 2017 Ram could have an aluminum body, like the 2015 Ford F-150 coming this year, FCA CEO Sergio Marchionne said.

In a question and answer session after the all-day future-product presentation, an analyst wondered how quickly FCA could respond if the aluminum-bodied F-150 is a big hit.

“We’ll make the deadline. We can do aluminum in ’17,” Marchionne said. “We have the technology in-house.”

With Fiat Chrysler now on board, that’s three big truck manufacturers (Ford and GM as well) using aluminum for their heavy-duty vehicles. Perhaps the next wave will see entry into the next heaviest segment: the SUV market.

1 05, 2014

Jaguar Shares Aluminum Secrets For Industry Benefit

2017-01-26T23:37:29+00:00May 1st, 2014|

It’s no secret that aluminum is becoming a go-to material for the auto industry. However, it’s uncharted territory for many manufacturers. Are individual companies keeping secrets? In fact, it’s actually the opposite — they’re sharing knowledge, lessons learned, and tricks of the trade when dealing with aluminum.

Why would they do this? It’s all about bringing the industry up to a new standard so that manufacturing costs decrease. From Automotive News:

Jaguar Land Rover would like the industry to adopt standards for raw materials and tools to assemble aluminum vehicles. These standards would cut production costs, and the changes won’t happen unless the big players get involved.

Mark White, Jaguar Land Rover’s chief technical specialist for aluminum, says automakers producing vehicles with aluminum — Audi, Mercedes-Benz, Porsche, and soon Ford — each use a slightly different manufacturing system that includes various grades of aluminum and different rivets, glue, robots and measuring systems.

For example, Jaguar Land Rover will buy 353 million rivets this year to assemble all of its aluminum-bodied vehicles. When production of Ford’s aluminum F-150 begins in the fall, Ford will be buying about 2 billion rivets per year, assuming each F-150 has roughly the same number of rivets as an aluminum-bodied Range Rover.

Being an industry leader is a great thing but leading innovation can be expensive. By sharing knowledge, new innovations can become standard, allowing manufacturers to focus

23 04, 2014

Report: Ford To Expand Aluminum-Based Lineup

2017-01-26T23:37:29+00:00April 23rd, 2014|

You can’t stop the aluminum momentum, you can only hope to contain it. At least, that’s probably what various materials manufacturers are thinking when it comes to the latest news out of Ford. The F-150’s aluminum body has been in the works for several years now, and it’s logical to think that Ford has explored other avenues for integrating this MPG-friendly metal. However, Edmunds has grabbed word that Ford’s 2015 lineup is going to be a little more aluminum friendly. From the Dallas Morning News:

According to Edmunds.com, Ford is considering converting the next-generation Expedition to aluminum body, as well as the strong-selling mid-size Explorer crossover.

If the Expedition gets an all-aluminum body, the Lincoln Navigator likely would, too, since both are built on the F-150 pickup platform.

Both vehicles weigh about 5,500 pounds. Ford unveiled the 2015 Expedition at the Dallas Auto Show in March, which will be equipped for the first time with the company’s 3.5-liter EcoBoost V-6.

While Ford did not release any fuel-economy numbers for the new Expedition, they should be better than the current 5.4-liter V-8.

Of the major American auto manufacturers, Ford has been the most public about going to aluminum. However, with Ford expanding its aluminum-based fleet, it seems sensible to think that we’ll be hearing more about this soon from other companies.

17 04, 2014

Aluminum Repair Drives Evolving Body Shop Workload

2015-06-18T15:33:05+00:00April 17th, 2014|

More and more auto manufacturers are looking at aluminum as a significant portion of a vehicle’s body. But what happens after the car hits the road and requires repairs? Body shops are discovering that they need to quickly get with the times in order to keep up. From Body Shop Business:

Ever since Ford announced the release of its new F-150, aluminum seems to be the talk of the industry. Due to Corporate Average Fuel Economy (CAFÉ) standards requiring automakers to produce more fuel-efficient vehicles, the maker of America’s best-selling vehicle turned to military grade aluminum alloy to make it 750 lbs. lighter.

But some shop owners aren’t too enthusiastic about the change. For one, purchasing special equipment to properly repair aluminum is a significant investment – one that some speculate will offer little to no return.

“The biggest challenge facing repairers isn’t becoming capable in aluminum repair; it is the downward pressure being placed on repairs from an expectation that somehow we are able to do more, and invest more, for a lesser return,” said Aaron Schulenburg, executive director of the Society of Collision Repair Specialists (SCRS).

Dan Risley, president and executive director of the Automotive Service Association (ASA), estimates that less than 20 percent of the industry is ready to perform structural repairs on aluminum vehicles.

“I think a larger portion of the industry is capable of repairing non-structural aluminum parts, but they aren’t equipped to do it. Unfortunately, many of them aren’t properly equipped to do it.”

While the return on investment won’t just magically appear overnight, Risley says that the shops that make the investment in equipment and training will be the ones that survive in the end.

“It probably doesn’t make financial sense for [shops] to pursue it today if they don’t have the capital. However, it will start to even out as more mainstream vehicles, such as the Ford F-150, are manufactured. If you don’t do this at some point, you’re going to be blocked out from repairing those cars.”

And it’s not just the customers who will take their business elsewhere – shops will be facing increased scrutiny from insurance partners, too.

“Insurance companies are going to start identifying which shops are equipped and trained to repair [aluminum] cars,” said Risley. “So if you’re a shop that’s reliant upon direct repair referrals, quite frankly some of those referrals will never make it to your door because you can’t properly repair the vehicle.”

As with any industry, staying ahead of trends is the key to survival. As aluminum becomes more and more of an industry standard, the proper training and equipment for body shops will become a fact of life, not just a luxury.

10 04, 2014

Recycled Aluminum Saves Ford On Manufacturing Costs

2017-01-26T23:37:29+00:00April 10th, 2014|

Recycling is good for the planet. It can also be good for your wallet, at least when you lug in a bunch of cans to the recycling center — or, if you’re in the manufacturing business, when you want to recycle materials. That’s what Ford did when they started putting together the 2015 F-150, and their recycling processes actually shaved about 20% off of the final aluminum materials cost. From Car & Driver:

When Ford announced earlier this year that its new F-150 would employ aluminum for the majority of it’s construction, speculation that insurance, repair, and manufacturing costs would increase began to circulate almost immediately.

We investigated the first two concerns at the time, finding them to be less disconcerting than originally expected, and, judging by the majority of comments from our Backfires members, the enthusiast community agrees with us. But to be fair, it will be at least a year after the aluminum F-150 goes on sale before enough real-world data enters the information stream to completely understand the cost implications. Now, according to an article in Automotive News, Ford has found a way to improve efficiency on the manufacturing side via innovative recycling methods, saving the maker $124 per pickup truck as compared to traditional recycling methods, and cutting the per-truck cost of switching to aluminum to $750.

In short, the scrap from manufacturing gets recycled into usable aluminum for further manufacturing. It’s that type of innovation that is pushing the F-150 to the spotlight for both auto industry watchers and environmental pundits.

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