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.

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.

2 04, 2014

Tesla’s Aluminum Shield

2015-06-18T15:33:05+00:00April 2nd, 2014|

The only blip on Tesla’s radar over the past year or so has been that pesky battery fire problem. While these incidents have made for some spectacular videos, the truth is that they  occur in statistically minimal amounts. However, Tesla’s known for their innovation and attention to detail, and considering the coverage this issue has gotten, it’s no surprise that they’ve responded quickly – and aluminum is part of the solution. From CleanTechnica:

In response to two road debris-induced road fires that were front page news, Elon Musk announced the Tesla Model S will get a titanium-reinforced underbody shield. That should silence the haters and doubters who thought the Tesla was a firetrap.

All new Tesla Model S sedans built after March 6th have been equipped with the new battery shield, and existing Model S customers can get the upgrade, free of charge. The battery shield consists of three separate layers of aluminum and titanium designed to deflect and absorb energy from road debris before it ever reaches the battery pack.

Head over to CleanTechnica for videos of this new shield in action. If this issue was causing you to hesitate on purchasing a Tesla, the new shield might just change your mind.

26 03, 2014

Aluminum Closures Gaining Popularity On Wine Corks

2015-06-18T15:33:05+00:00March 26th, 2014|

Twist-off caps may represent a stereotype of lower-grade quality when it comes to wine bottles. However, these aluminum-based closures are actually gaining in popularity, particularly in Europe, which means you’ll have to shed any preconceived notions about them when purchasing wine.

Why are wine drinkers leaning towards twist-off caps? Thanks to the world moving towards greener materials, aluminum closures are recognized for their recyclability (you can also save the wine for later, which is always a bonus). From Greener Package:

When it comes to wine and spirits closures, a majority of European consumers prefer aluminum over other options. That’s according to a recent survey of 6,000 consumers conducted by market research company IPSOS.

The study, which took place in five major European markets—France, Germany, Italy, Spain, and the U.K.—as well as in the U.S., was commissioned by members of the EAFA Closures Group, part of the European Aluminum Foil Assn. (EAFA).

Other results of the study show that aluminum closures received top scores when consumers were asked about their preferences for reclosing a bottle of unfinished wine for later consumption. Four out of 10 surveyed confirmed they had poured away wine from a bottle closed with a cork closure that had been tainted or had gone bad.

When asked to compare their purchasing intentions of the same bottle of wine with different closures, more than one-third said they would prefer to buy wine with an aluminum closure, and a quarter said the type of closure would not influence their purchase.

At present, only 30% of consumers connect easy and complete recyclability with aluminum closures. This supports the industry’s continuing efforts to more proactively promote the advantages of recycling, as already in Europe, more than 40% of aluminum closures are recycled.

Wine snobs of the world, look out! Aluminum’s coming your way, and it may even be hauled in an aluminum-based Ford F-150!

20 03, 2014

Mercedes Benz Goes Aluminum

2015-06-18T15:33:05+00:00March 20th, 2014|

The Ford F-150’s body made plenty of waves across the automotive industry as one of the first mainstream entries in the aluminum revolution. As everyday work trucks go, it doesn’t get much more all-American than that. But what about the world of luxury cars? Turns out Mercedes Benz is thinking of turning to aluminum as well. From World Car Fans:

 

Mercedes-Benz S-Class chief engineer Hermann-Joseph Storp has shed some light about the company’s next-gen flagship model.

 

Mercedes-Benz still hasn’t finished coming out with derivatives of the W222 S-Class but they have already started thinking about the next generation scheduled to come out before the end of the decade. During a press gathering this month at Geneva Motor Show, company chief engineer Hermann-Joseph Storp said Mercedes-Benz will focus on making the S-Class even greener and one way would be to use more aluminum and carbon fiber reinforced plastics (CFRP) in the car’s construction.

 

While the W221 S-Class used just over 10 percent of aluminum in its body, the new one is almost half made from aluminum.

 

With news like this, it’s clear that aluminum is becoming part of the standard across all spectrums of cars. If it’s good enough for the rugged duty of a Ford F-150 and the premium expectations of a Mercedes Bens, then it shouldn’t be long until you see it in everything in between.

12 03, 2014

Two Months Later: What Has Ford Learned About Aluminum?

2017-01-26T23:37:29+00:00March 12th, 2014|

These days, aluminum and the Ford F-150 are pretty synonymous. Since the big reveal a short while back, the automotive industry has been buzzing and Ford has been in the media non-stop answering questions and responding to comments about the topic.

 

At the recent 2014 Geneva Motor Show, Ford executives reflected on the past two months since the reveal, and Motor Trend has it covered:

 

Mark Fields, Chief Operating Officer: This Was Not A Risky Bet

“Well the first thing we learned is people really like it… not only the response at the show, but obviously in looking at the blogs, in looking at the comments. I think people love the design, because it’s very progressive.

 

They’re very curious around… tell me more… tell me more about the payload, towing, fuel economy, things of that nature. So it’s been a lot of learning around that, which is really helpful for us as we look at our go to market strategy. So we’re very pleased with the response we’ve had so far.

 

Jim Farley, Executive Vice President, Global Marketing, Sales, Service and Lincoln: About The Repair Training Program

“I think we learned a lot to be honest. There was a lot more questions about repairability, so we’ve suddenly had to take our service engineering team primetime with the media now.

 

“We are about halfway into signing up the number of dealers that we need for the repairability. You know about 20% of the repairs for full size trucks are done by dealers, about 80% are independent repair body shops. We signed up about 400 dealers now – I think it’s just shy of 500 dealers – and so we’re about halfway to our goal. And we’ll have that training done by the third quarter, and all the equipment installed, the rivet guns, the MIG welders, all the containment

[gear]…

 

For much more, including further responses from Fields and Farley, as well as input from Global Product Development Vice President Raj Nair, see the full article.

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