5 01, 2015

Cadillac’s New Flagship Vehicle Will Have An Aluminum Body

2015-06-18T15:33:03+00:00January 5th, 2015|

It’s safe to say that the aluminum revolution has begun for American automakers. With the Ford F-150 rollout hitting a full stride, news has come out that Cadillac’s luxury sedan line will soon be making good use of our favorite metal. According to Automobile Magazine, the new Cadillac CT6 will feature an aluminum body when it gets unveiled in the near future.

Will the new Cadillac CT6 have the rakish, expressive styling of the Elmiraj show car, or will it be a conservative evolution of the luxury brand’s current design language? While those questions will linger probably until the CT6 is unveiled later in 2015, AUTOMOBILE has learned this about the sedan, which uses General Motors’ new Omega full-size rear-wheel-drive platform: It will have an aluminum body.

The Cadillac CT6, which will be a bit smaller than a Mercedes-Benz S-Class but larger than the midsize CTS, also will be the first to use an engine, or engines, from GM’s upcoming four-/six-/eight-cylinder family. We have learned that while a CT6 Vsport has been approved for production, there’s no word on a CT6-V yet, so some sort of turbocharged- or supercharged-six seems likely.

The aluminum body, which potentially keeps the new sedan in or close to the CTS’s 3,700-4,100-pound weight category, suggests that the CT6 is designed to aim for the Mercedes CLS-Class, BMW 6 Series Gran Coupe, and Audi A7 even if its styling doesn’t classify it as a so-called four-door sport coupe.

The new CT6 is expected to be revealed at car shows during the first half of the new year. Expect a lot of hype and press, as Cadillac has already called the sedan its new flagship vehicle.

23 12, 2014

Aluminum Powers New High-Speed Rail Technology

2017-01-26T23:37:28+00:00December 23rd, 2014|

Would you speed across the rails in a train car made of aluminum foam?

Sounds like a risky proposition, but it’s actually safe, strong, and mass-efficient. All of these things make this new aluminum-based composite one of the most exciting innovations the mass transit industry has seen in years. From Wired:

Americans have long been promised high-speed rail, but to date, we’re still far behind Europe and Asia when it comes to rolling stock. Now, we have one more train technology to envy our brethren across the pond: Trains made of aluminum foam, a material that’s stronger, lighter, and better in a crash than fiberglass or regular old metal.

Engineers in Chemitz, Germany unveiled a prototype high-speed train cab made with the stuff earlier this year. The composite material is built like a sandwich: Between two pieces of aluminum, each just two millimeters thick, is a 25-millimeter-thick layer of the “foam,” actually a low-density, sponge-like composite of magnesium, silicon, and copper, and aluminum. And like a good sandwich, there’s no glue. The layers are held together by metallic bonding, the electrostatic attraction of negatively charged electrons and positively charged ions.

The result is a material that’s 20 percent lighter than traditional fiberglass, which is commonly used on high-speed train cabs. That’s a big advantage when the goal is to move faster and more efficiently. Even better, it doesn’t come at the cost of a weaker train. “The outer shell is so stiff that you need no ribs inside,” says Dr. Thomas Hipke, head of lightweight construction at the Fraunhofer Institute for Machine Tools and Forming Technology, which helped to design the prototype train cab. Peel tests of aluminum foam—in which force is applied to pull apart the layers of the material—destroy the foam interior instead of breaking the bonds between the layers, demonstrating the strength of the bonding.

To the layperson, the idea of 200 MPH inside of an aluminum-based tube sounds frightening. However, the science behind it is solid: it’s safer and more efficient than traditional materials, meaning that it gets the job done while being less taxing on our energy resources. Just like the Ford F-150, it’s another breakthrough innovation thanks to aluminum.

18 12, 2014

Ford Sees Recycling As Key To New F-150

2015-06-18T15:33:03+00:00December 18th, 2014|

It’s already well known that the Ford F-150’s body switched from steel to aluminum, but now further details are coming out regarding the actual manufacturing process. It turns out that Ford’s decided on a zero-waste system when it comes to aluminum thanks to the metal’s recycling capabilities. Not only does this result in a cost savings for the company, it helps minimize the amount of resources used and wasted during manufacturing. From the Wall Street Journal:

The 2015 F-150, perhaps the most important vehicle to hit Ford dealerships in decades, goes on sale this month. By the time a new truck exits the factory and heads for the showroom, it will have left behind $300 worth of scrap aluminum on the plant floor.

That scrap is collected, cleaned, and sent back to the aluminum plant on the same trucks that delivered it fresh—creating what Chief Executive Mark Fields calls a “closed loop” that helps offset the expense of building its best-selling vehicle with a material that is far pricier than steel.

“Every single scrap of aluminum is reused,” Mr. Fields said in an interview. “The more you can reuse or recycle, it makes it a more compelling business case.”

Every day, about 50 semi tractor-trailers drive out of Ford’s F-150 plant in Dearborn, Mich., with thousands of pounds of shredded aluminum, scrap that was stamped out of six-foot-wide aluminum rolls used to make F-150 body panels. Only 60% to 65% of a roll is actually used in the stamping process because many body panels have big holes, such as windows.

Because aluminum can be recycled almost endlessly without degradation, recycling has long played a major role in the production of everything from beer cans to jumbo jets. The twist is that Ford installed systems to separate the six different aluminum alloys it uses and return them to mills in Iowa or New York, to be turned back into aluminum sheet for delivery to its Dearborn stamping plant.

For more on the technology behind Ford’s recycling process, be sure to check out the full WSJ article.

12 11, 2014

Aluminum-Based Ford F-150 Hits Manufacturing Floor

2015-06-18T15:33:03+00:00November 12th, 2014|

It’s time to put all of the testing and speculation aside. Ford’s aluminum pride and joy, the 2015 F-150, has finally gone into full production, and the first vehicle off the assembly line got a rousing ovation at the Dearborn, Michigan facility. From the Detroit News:

Shortly before 10:45 a.m. Tuesday, Dearborn Truck plant manager Brad Huff and UAW Vice President Jimmy Settles drove the first 2015 F-150 pickup — painted cherry red — off the assembly line and into history.

Ford Motor Co.’s newest truck, made with an aluminum body and bed that saves up to 700 pounds, marks a significant milestone for the Dearborn automaker and is a potential game-changer for the industry. The launch completes years of research and development after Ford overhauled nearly every aspect of the building process from exterior painting to interior design.

The lightweight material is expected to increase gas mileage 5 percent to 20 percent, but is more costly to make and repair — a big gamble for Ford’s best-selling vehicle. The launch also marks a rebirth for the Dearborn Truck Plant, centerpiece of the venerable Rouge Center that was nearly shuttered before finding new life to build the truck. The plant underwent a multi-million dollar renovation this year.

“We’re here today to make history,” executive chairman Bill Ford said as hundreds of workers cheered. “The Rouge has always been at the heart of Ford to me and my family.”

Now that production is in full force, showrooms are expecting to get their inventory sometime within the next month. The early word in reviews and press has been positive, but the ultimate vote comes down to the consumer. With its increased gas mileage and signature durability, we’re guessing it will be a winner.

16 10, 2014

(Really Expensive) Aluminum Case Protects iPhone 6

2017-01-26T23:37:28+00:00October 16th, 2014|

You’ve bought a shiny new iPhone 6 but with horror stories of bent phones, you’re afraid to put it in your pocket. Never fear; for $2,000, Gresso has an aluminum case that’s built to withstand the rigors of life in a back pocket. From GSM Arena:

Bendgate is the latest

[something]gate to plague the iPhone and Gresso has a case to cure that problem. The case is for the iPhone 6 rather than the 6 Plus, which is actually the one with bending issues.

Still, Gresso is known for its luxury phones and a lot of machining went into the making of the Gresso Aluminum Bumper for the iPhone 6.

It was machined out of aircraft-grade anodized aluminum and features a patented hinge mechanism to clasp both the front and back of the device.

The case increases the force needed to bend the iPhone 6 from 70lbs to 300lbs.

The most important part of the article? “The bumpers are available in grade 5 titanium and 18K yellow or white gold. Prices start from a wallet-clenching $2,000.” Better start saving those pennies. Of course, by the time you can afford a $2,000 case, the iPhone 7 might be out!

Click on through to the original post for a video of this test in action.

10 10, 2014

News Roundup: Ford’s Aluminum Gamble Pays Off

2015-06-18T15:33:04+00:00October 10th, 2014|

All sorts of Ford F-150 news today as we creep toward the official street date. Here’s a roundup of some of the latest aluminum-related news:

From Gas 2: “2015 Ford F-150 Curb Weights Revealed”

…the lightest 2015 F-150 you can buy is two-wheel drive regular cab model with the naturally-aspirated 3.5 liter V6, which comes in at a svelte 4,050-lbs. That, my friends, is actually lighter than the 556 horsepower Camaro ZL1, which comes in at 4,160-lbs (about 300-lbs more than a stock Camaro SS), and I’ve got to hand it to Ford, that’s a pretty impressive feat. Even with the 5.0 liter V8, the regular cab 2015 F-150 comes in at just over 4,220-lbs, and the smaller all-new 2.7 liter EcoBoost V6 equipped models weigh in at 4,168-lbs.

From the Toronto Star: “If driving is believing, 2015 Ford F-150 is the best one yet”

Whether it’s a gamble or a game-changer is still up in the air, but Ford has announced that the next-generation Super Duty will also have an aluminum body. And you better believe the other truck companies will crunch those fuel and capacity numbers when they’re finally announced. But driving is believing, and after my time behind the wheel, I think that for performance and handling, this new F-150 is the best one yet.

From the New York Daily News: “Test Drive: 2015 Ford F-150 aims to redefine the pickup truck segment”

But the new Ford’s aluminum construction and turbocharged V-6s make it the most technologically advanced full-size pickup, and the weight savings pay off in increased capability and, most likely, improved fuel economy. Considering those strengths, this advanced new Ford pickup should have no problem maintaining its sales lead. It looks like Ford’s gamble was a good one.

 

The official specs are impressive and the early reviews are backing it up. Looks like Ford’s investment in aluminum is paying off — and the rest of the industry will soon

2 10, 2014

Six New Facts About The Aluminum F-150

2015-06-18T15:33:04+00:00October 2nd, 2014|

We’ve been talking about Ford’s aluminum-based F-150 in broad strokes for quite some time now. As we inch closer and closer to the public street date, news outlets are getting more facts and figures about the bestselling truck line in America. Let’s see what USA Today found out in a recent report:

  • Sign-makers are working up removable, sticky-film decals because magnetic signs won’t stick to aluminum. You’ll still be able to proclaim, “My kid’s an honor student,” or, “Best Gutter Cleaning in Three Counties” using the new slap-on appliques that independent retailers expect to be selling soon.
  • Aluminum body didn’t cut 770 pounds of weight. About 500 pounds. The rest is from lighter steel frame, heavy use of high-strength, lightweight steel throughout the truck. The frame is 78% high-strength steel, up from 22% in the 2014 F-150.
  • The 2.7-liter EcoBoost V-6 Ford’s promoting as a good blend of power, mileage will be a $495 option when the truck’s launched late this year. discounted from the $795 sticker price to get dealers to order the engine and buyers to consider it. Power ratings: 325 horsepower, 375 pounds-feet of torque at 3,000 rpm. It will be able to tow 8,500 pounds. No official mpg ratings on it or the other powertrains until November. The 2.7 engine also will be offered as the high-performance choice in the new version of the Ford Escape Sport.

USA Today has three more F-150 facts in the original article, so click through to it and find out more about how aluminum has changed America’s bestselling truck.

12 09, 2014

Ford Tours F-150 To Show Off Aluminum-Built Toughness

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

Ford knows that there are skeptics out there regarding the aluminum-built F-150 despite good numbers and strong buzz. To help get dealers ready for the big launch, the company is bringing the F-150 around the country to prepare dealers for questions and concerns from a curious public. From Fox Business:

Ford Motor Co. (F) is putting its new aluminum-bodied F-150 to the test.

FOX Business got an exclusive look at a demonstration event featuring the 2015 F-150, which is expected to go on sale later this year. Ford is visiting 26 cities to introduce the pickup truck to sales personnel.

The aluminum truck has been the talk of the auto industry since it was introduced at the Detroit auto show in January. Few production cars are made almost entirely of the lighter metal. The F-150 will be the first truck to use an aluminum body.

By switching from steel, Ford cut 700 pounds from the nation’s best-selling pickup. While the company has yet to release fuel economy estimates, analysts widely expect the 2015 F-150 to get better gas mileage than previous versions.

At the demonstration in Romeo, Mich., Ford pitted its F-150 against the Chevrolet Silverado and GMC Sierra from General Motors (GM), plus the Ram 1500 from Chrysler Group.

“We want our sales consultants to have confidence that this new truck is just as capable,” Eric Peterson, Ford’s F-150 marketing manager, told FBN’s Jeff Flock. “It’s got great performance and great capability just like the current truck. That’s what they get to experience firsthand.”

The F-150 is set for public launch later this year. Expect to see official numbers regarding MPG shortly before the launch.

6 08, 2014

Jaguar Ready To Deploy Aluminum Architecture

2015-06-18T15:33:04+00:00August 6th, 2014|

Jaguar is ready to commit full-scale to aluminum. The British automaker recently announced that its new line of vehicles will be based on a new flexible aluminum architecture. Jaguar is looking at the Paris auto show in October to unveil the first of this line. From Automotive News:

Jaguar is moving to a new flexible aluminum architecture for future vehicles.

The XE sedan debuting in October at the Paris auto show will be the first to use the architecture. It will be followed by a compact crossover that will take styling cues from the C-X17 concept unveiled last fall at the Frankfurt auto show.

From there, Jaguar will expand its lineup, with the goal of transforming the brand into a formidable competitor with the German makes. But Jaguar executives insist the brand won’t develop vehicles in every segment. They say they want Jaguar to remain a smaller player than its competitors.

Older vehicles such as the XK coupe and convertible, which would cost too much to engineer to meet new safety and emissions standards, are being killed off. The 2015 models will be the last for the XK coupe and convertible. Jaguar’s halo cars are now the F-Type coupe and convertible. U.S. sales of the coupe began in June. The convertible went on sale a year earlier.

While the aluminum body hasn’t yet trickled down to all of Jaguar’s vehicles, industry insiders believe it’s just a matter of time before the transition is made. For example, the popular XF line will see a redesign in the next 1-2 years, and it makes sense that Jaguar will use that as the aluminum transition point for design and manufacturing.

30 07, 2014

2015 Ford F-150 Prices Announced

2015-06-18T15:33:04+00:00July 30th, 2014|

August is here, and with it, the F-150 is getting closer to its public launch. You can tell the momentum is picking up as more publicity and news hits the wire. The biggest news, however, just came from Ford: the price. From the LA Times:

Ford has announced pricing on its groundbreaking new aluminum F-150 truck, due to reach dealers later this year. Though cheaper models will see only a modest increase in price over current, non-aluminum models, the price of Ford’s high-end editions will jump by more than $3,000.

The new 2015 F-150 XL will start at $26,615, while the XLT will start at $31,890. That’s a gain of $400 for each version, which together make up about 70% of all F-150 sales. The price of the midlevel Lariat is up $900 to $39,880, which includes a fully digital instrument panel and blind-spot monitoring.

At the high end of the F-150 lineup are the King Ranch and Platinum models. The 2015 King Ranch edition is up $3,615 to $49,460. The 2015 Platinum model will start at $52,155, an increase of $3,055.

Many observers expected a modest increase due to new manufacturing and materials, and there’s certainly some variation here. However, keep fuel savings in mind when you look at the big picture (official MPG hasn’t been released yet but is expected to be higher than 2014’s 17/23).

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