12 08, 2014

CNBC: Aluminum’s Time To Shine

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

With such an intense focus on the auto industry and the launch of the Ford F-150, it’s easy to lose sight of the bigger picture: that aluminum as a whole is used many different types of manufacturing all over the world. From that perspective, the momentum is as strong — if not more — than the microcosm of the auto industry. CNBC recently highlighted this in a report, and the outlook is very positive.

From CNBC:

As sentiment turns increasingly bullish towards aluminum amid a backdrop of tight supply, analysts say the once-shunned base metal is finally at a turning point.

The metal has been trading near seventeen-month highs above $2,000 per ton in recent weeks and entered a bull market in late July, up more than 20 percent since a 2014 low of $1,677 in February.

“We’re probably now at a point where the aluminum market may be turning and that has everything to do with supply shutting down in China and as supply-demand re-balances across the entire industry,” Gaurav Sodhi, resources analyst at Intelligent Investor, told CNBC on Thursday.

For a more detailed look at the world aluminum market, including the impact of recent movement in the Chinese manufacturing industry, see CNBC’s full article.

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).

18 07, 2014

Auto Industry Sees F-150 As Aluminum Catalyst

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

The launch of the new Ford F-150 (AKA our favorite topic over the past year or so) was the biggest step towards mainstream usage of aluminum in by auto manufacturers. While the unveiling was met with a mix of excitement, curiosity, and skepticism, the reviews wound up showing that Ford made the right choice. Now, the popular opinion has changed — rather than the F-150 being Ford’s giant gamble, automakers around the world see it as a critical choice that will change the industry. From the Detroit Free Press:

 

By 2025, 18% of all vehicles will have all-aluminum bodies, up from less than 1% now, according to a recent report from Ducker Worldwide.

 

The industry is now engaged in a conversation about the pratfalls and possible solutions of using aluminum on a high-volume vehicle. The challenges are being solved with new ways of joining aluminum and steel, manufacturing with speed and efficiency, crashworthiness and repairability, cost and consumer acceptance.

 

Ducker forecasts that next-decade aluminum will be used for 75% of the panels and parts on pickups, 24% of large cars, 22% of SUVs and 18% of minivans.

 

The F-150 is an industry catalyst, said Gary Silberg, national auto industry leader at KPMG. “They’re figuring it out. People are studying it and making it a reality.”

 

From questionable decision to industry catalyst — the F-150 has come a long way since its unveiling at the Detroit Auto Show, and it hasn’t even gone on public sale yet. But in the coming months, people will be able to find out for themselves. Chances are, they’ll be just as impressed as the rest of the industry.

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!

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.

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