LIGHTWEIGHTING

Rolled Aluminum Producer Novelis Expands NY Plant

May 25, 2016 by admin Leave a Comment

Ford Super Duty benefits from Novelis aluminum.

2015 Ford F-150. — This aluminum Ford F-150 will soon be joined by an all-new Super Duty.

“Vehicle lightweighting” is one of those industry buzzwords that doesn’t easily roll off the tongue. Outside of the auto industry, few people are familiar with the term. But if you mention “Ford F-150” then the recognition is instantaneous — nearly everyone knows the current generation model has a weight-saving aluminum body.

Well, like all other manufacturers the Ford Motor Company relies on suppliers to provide them with the materials to form vehicle bodies. Most manufacturers use steel body panels and plastic front and rear fascias. Carbon fiber is also used, but in very limited quantities, while aluminum is now in greater use than ever before.

Automotive Market Served Well

Novelis is the leader in all things rolled aluminum products and also has the distinction of being the largest recycler of aluminum in the world. On the automotive front, the company supplies aluminum to Audi, BMW, Cadillac, Jaguar, Land Rover, Mercedes-Benz, as well as to Ford. Coca-Cola, LG, and Samsung are among other companies making use of Novelis aluminum.

Increased demand for aluminum is part of automakers’ overall sustainability strategy, an effort to reduce vehicle weight and lessen the impact on the environment. To that end, Novelis has opened a third cutting edge automotive finishing line at its plant in Oswego, New York.

The latest line was installed to assist the production of durable, lighter and safer vehicles, representing a $120 million investment to expand the high-strength aluminum alloy supply for Ford F-Series trucks. As a result of this expansion, the company has extended its stand as the preeminent automotive aluminum sheet supplier in North America.

“As a result of our investments across the globe, Novelis is able to offer our automotive customers unique advantages and benefits through automotive lines such as this one in Oswego,” said Steve Fisher, President and CEO, Novelis. “Automakers are seeking alternative materials to cut vehicle weight while maintaining strength and safety requirements. With investments in Asia, Europe and North America, Novelis has the global footprint, assets and expertise to meet the needs of automakers in every major auto-producing region.”

Benefitting the 2017 Ford F-Series

Novelis says the third and newest automotive finishing line will produce aluminum sheet for the body and cargo box of the all-new 2017 F-Series Super Duty lineup, enabling Ford to reduce the overall vehicle weight by up to 350 pounds. As a result, the new truck is expected to deliver improved hauling and towing capabilities.

“Novelis works closely alongside our automotive customers to meet their precise and exact demands,” said Marco Palmieri, SVP and President, Novelis North America. “The passion for excellence among our employees in Oswego and throughout North America has made possible this latest automotive expansion. It is a testament to our commitment to help our automotive customers bring to market the lightweight vehicles of the future.”

Expanded Footprint, More Jobs

Over the past five years, Novelis has expanded its ability to serve the North American automotive industry by installing and commissioning three automotive finishing lines in Oswego, adding at least 460 jobs. The current $400 million investment also includes the world’s largest closed-loop recycling program, which processes roughly 25 million pounds of automotive aluminum scrap per month.

Besides its plant in New York, Novelis has a strong presence in Ontario, Switzerland, Germany, and China, and claims to be the only manufacturer of high-strength, military-grade aluminum with a presence in all three major auto-producing continents. Lastly, Novelis says its automotive aluminum can now be found in more than 180 vehicle models currently produced by automakers.

Forecast: 7 Top Auto Trends for 2016

December 31, 2015 by admin Leave a Comment

We take a look at what may become the top auto trends for 2016.

2016 Chevrolet Camaro. (photo copyright GM Corp.)

This year (2015) will go down as one for the books. Specifically, it will be a sales record breaker once the books have been closed on Jan. 4. That means on Tuesday we’ll know which model was the best selling car (Toyota Camry), the best selling truck (Ford F-150), and the best selling luxury brand (BMW). Sorry for the spoilers.

Since the market bottomed out in 2009, consumers have been snapping up new vehicles, especially crossovers. Manufacturers continue to roll out new models along with the latest technologies and safety features.

If you haven’t purchased a car in at least a decade you’ll find a long list of included or available amenities not offered way back when. To that end, we’ll look at some of the top auto trends for 2016 and the impact of such trends.

1. Car sales continue to rise.

We’re due for an economic downturn, but that drop may still be more than a year away. If so, then look for US auto sales to top 18 million units in 2016, setting yet another record.

Although the Federal Reserve Bank has raised interest rates by 0.25 percent, the effect on consumers should be negligible. What is helping nearly everyone is low gas prices. As long as regular grade gasoline averages $2 per gallon or less, consumers will save hundreds of dollars per year.

2. The presidential election will become a factor.

No matter who the Democrats and Republicans serve up as their candidate, we’ll have two people who will be more alike than different. A number of policy issues will be discussed and debated; creating jobs for Americans will remain a top issue.

Expect both candidates to promise the moon, even if they can barely deliver on those promises. Expect a new administration to carefully review the fuel economy standards, perhaps proposing a rollback of the 54.5 mpg mandate that nearly all manufacturers will find tough to implement by 2025. That rollback, however, won’t occur before the new president takes office in January 2017.

2016 Volvo S60 Inscription

The made-in-China Volvo S60 Inscription.

3. Chinese-built cars will increase in numbers.

It wasn’t too long ago that the thought of Chinese-built cars reaching the North American market had some people up in arms. After all, how could any manufacturer compete against a $6,800 Geely? Then again, what junk would be foisted upon consumers at such a low price point?

Well those fears are unfounded. First, no Chinese manufacturer has entered the market all by itself. Second, the cars that are imported from China are from known manufacturers. For instance, the Volvo S60 Inscription, a stretched wheelbase model, is made in China. The Chinese-made Buick Envision arrives this spring.

Although the floodgates aren’t about to open, you’ll see more products from different places thanks to the Trans-Pacific Partnership Free Trade Agreement (TPP), which is expected to be signed in February. You can also expect strong push-back against TPP from both sides of the political aisle.

See Also — It’s a Wrap: 2018 in Review

4. Automotive lightweighting goes mainstream.

Okay, vehicle lightweighting is nothing new. Its just widely misunderstood.

A case in point — when I inquired at a recent automotive media event regarding lightweight properties for a new pickup truck, my hosts didn’t seem to understand my question. That question was further clouded when a colleague quipped, “They didn’t want to make it lighter because it is a heavy duty truck.” Sigh.

Car manufacturers, however, get lightweighting. They’re also working with elastomer manufacturers around the world to incorporate nitrile butadiene rubber in under-the-hood applications. As long as these and other materials are cost-effective, recyclable and practical, then greater adoption will continue throughout 2016 and well beyond.

2015 Ford F-150

The current-generation Ford F-150 is the poster model for all things lightweighting.

5. The lurch to autonomous driving continues.

The experts tell us that autonomous driving will arrive in 2020. That means within five years we’ll see the first driverless cars take to the road. That also means the beginning of the end for behind-the-wheel driving. Or does it?

No doubt, some type of autonomous driving will be in place, but with more than 250 million registered vehicles in the US, the percentage will be small, quite possibly matching the adoption rate for electric vehicles. Consumers won’t give up their cars en masse for several reasons, including wanting to keep the cars they love as well as not being able to afford the attendant higher cost for autonomous vehicles.

Politically, a backlash against autonomous vehicles may emerge, especially if consumers grow weary of the intrusiveness — perceived or otherwise — that emerging technologies bring, particularly in the form of privacy. Instead of a wholesale adoption of autonomous cars, a number of safety features will be standard. We’ll see adaptive cruise control, automatic braking, and lane keep assist in more models in 2016.

6. New alliances and partnerships emerge.

We’re seeing more alliances emerge across the auto industry and that pace should continue in 2016. Such agreements will be forged to give manufacturers an edge wherever needed. Toyota and Mazda hooking up essentially keeps the latter in the ultra-competitive US market for the long haul while giving Toyota much needed product (Scion iA) for a low cost. Mazda will soon benefit from Toyota hybrid technology; both manufacturers will probably share Mazda’s SKYACTIV technologies to some degree.

I won’t predict where those alliances will emerge, but figure that any product holes will be filled by such agreements. Mitsubishi, if it is to survive in the US, must find a partner to supply a midsize sedan, share in EV development, and otherwise fill out its weak portfolio. Today’s strange bedfellows may become tomorrow’s partners.

2016 Scion iA

The Scion iA is the result of a partnership between Toyota and Mazda.
(Photo copyright Toyota Motors).

7. Technologies begin to work as touted.

If you have purchased a car within the past two or three years, the telematics system may be one of your least favorite options. Consumer surveys conducted by J.D. Power have amplified that frustration, thus getting it right will give manufacturers a much-needed edge in luring on-the-fence shoppers.

Helping matters are two technology giants — Google and Apple. Both companies are vying for dashboard access with Google Android Auto and Apply CarPlay enabling ease of smartphone integration. Where manufacturers are slow to adopt either, third-party audio systems such as Pioneer and Kenwood are making units compatible with both. Thus, if you have an older car, you can enjoy that access and avoid buying a new car.

Top Auto Trends

Other top auto trends will have little to do with your car, at least directly. Most will have to do with buying a vehicle, with leasing likely to continue to grow in numbers, while long-term auto loans of up to 84 months become more common.

Of course, if any major international crisis erupts, then these predictions should be amended or tossed.

MPG Leader Mazda Does it Without Hybrids or EVs

December 18, 2015 by admin 1 Comment

The Mazda brand has once again achieved the top miles per gallon (mpg) rating amongst all manufacturers in the US, reaching a fleet-wide average of 29.4 mpg for 2014, according to a report published by the EPA this week.

2016 Mazda CX-5

2016 Mazda CX-5.

SKYACTIV Technology Leads the Way

For the third consecutive year, Mazda beat out all comers and did so without the usual hybrid and electric vehicle models other manufacturers rely upon to achieve higher numbers. Instead, the company has been working diligently to improve its engines and transmissions, what it calls “SKYACTIV Technology”. The technology also extends to vehicle platforms as extensive lightweighting and sleek designs are employed.

“At Mazda, driving matters and so does fuel economy,“ said Jim O’Sullivan, president and CEO, Mazda North American Operations. “Using SKYACTIV Technology, Mazda has been able to achieve class-leading fuel efficiency in nearly every segment it competes in. This achievement verifies that Mazda has evolved to offer what others can’t, vehicles that are of high-quality, great looking, fun-to-drive and fuel efficient.“

Besides exceptional fuel efficiency, the EPA noted that Mazda is the leader in CO2 emissions, specifically the manufacturer offering the lowest output of all. With a rating of 302 g/mile, the automaker easily outpaced the next two brands, Subaru and Hyundai.

2016 Mazda CX-3

2016 Mazda CX-3.

New Product Offerings

Mazda’s success can be attributed to a host of new products released in recent years, including its compact Mazda3 and midsize Mazda6 car lines, its MX-5 Miata roadster, and a pair of crossover SUVs: the tiny CX-3 and the compact CX-5. Yet another model, the next-generation CX-9 arrives in 2016 and comes outfitted with a turbocharged, 2.5-liter engine, replacing the current V-6. The automaker expects the new CX-9 to deliver “great performance…and excellent fuel economy.”

Granted, Mazda is more of a niche player as it doesn’t match the product offers of the top brands, including Chevrolet, Toyota, Ford, Nissan, and Honda. The first four brands along with Fiat Chrysler are heavily reliant on larger SUVs and trucks, vehicles that skew mpg numbers accordingly.

Other Manufacturers Represented

Subaru, another niche manufacturer, came in second with a fleet-wide average of 27.6 mpg. This automaker relies on all-wheel drive models nearly exclusively, with only the rear-wheel drive BRZ lacking such a system. Subaru offers only one hybrid model: the XV Crosstrek.

Hyundai, with a fleet average of 27.5 mpg is another manufacturer with just one hybrid model: the Sonata Hybrid. This Korean manufacturer has no trucks and also has a relatively low presence in the utility vehicle segment. But it also has larger models such as the Genesis and Equus sedans that neither Mazda nor Subaru offer.

2016 Scion iA.

The Mazda-supplied 2016 Scion iA.

Among the largest manufacturers, Honda (inclusive of Acura) achieved a 27.3 mpg average. All three major US manufacturers brought up the rear with Ford and GM averaging 22.8 mpg and Fiat Chrysler coming in last at 20.8 mpg. These manufacturers dominate the full-size truck segment; FCA also lacks a hybrid or an electric vehicle (other than the California Fiat 500e) to help lift its numbers. FCA also finished dead last in CO2 output.

Incrementally Rising EPA Requirements

All manufacturers have a long way to go before reaching the 54.5 mpg corporate average fuel economy (CAFE) requirement for 2025. In fact, incremental year over year increases are mandated, therefore greater use of alternative fuels and power sources are likely, including for Mazda.

Beginning in 2016, Mazda will discontinue its last V-6 engine even as competitors continue to rely upon both V6s and V8s for some models. However, Mazda hasn’t announced what products will eventually get hybrids, but when it does the automaker will rely upon Toyota’s green technologies to achieve its goals according to Green Car Reports.

Vehicle Lightweighting Achieved Through Composites

October 1, 2015 by admin 2 Comments

Plastic has long been used in automotive manufacturing. These days, an assortment of composites are helping to reduce weight, save fuel, and decrease the number of parts used, including in the all-new Ford F-150.

Vehicle lightweighting is one of the more commonly aired terms used to describe how car manufacturers are reducing weight in a bid to boost fuel economy without sacrificing safety and performance. A variety of materials aid in the reduction of vehicle weight, including high-strength steel, aluminum, magnesium, carbon fiber composites, as well as plastics and polymer composites.

The US Office of Energy Efficiency & Renewable Energy says that for every 10 percent drop in vehicle weight, a corresponding 6 to 8 percent increase in fuel economy is attained. And with car manufacturers required to meet EPA-mandated fleet averages of 54.5 mpg by 2025, the race to replace heavier materials with lightweight composites is on.

American Chemistry Council

This past August, I was invited to participate in an exclusive tour of the Ford Rouge Factory in Dearborn, Michigan. Just six members of the press were on hand with an equal number of manufacturing professionals present to answer our questions.

Hosted by the American Chemistry Council in partnership with Ford, I was able to learn first hand how manufacturers such as Ford are employing weight reduction methods for their vehicles.

Ford Rouge was the ideal place to take that tour and for two reasons:

1) It is one of two manufacturing plants tasked with building the all-new and aluminum alloy intensive Ford F-150 pickup truck. The F-150 is a best seller and incorporates many other lightweight materials, with the result that up to 700 pounds were shaved from the previous model.

2) Just this past spring, a 2015 Ford F-150 SuperCab model entered my test fleet. As far as the road test was concerned, I already had a complete understanding of how the model performed. I also knew that aluminum played a big role in weight reduction, but beyond that, I wasn’t certain what other materials were used. The council-sponsored tour shed light on that.

Not Just Weight Reduction

Although weight savings is certainly important, there are other factors that fall under the “sustainability” umbrella that must be noted too.

For instance, Ford has been replacing some of its rubber components with a product known as Santoprene thermoplastic vulcanizates (TPV). Developed by ExxonMobil Chemical, Santoprene is part of a family of polymers and is used to replace the heavier thermoset EPDM rubber.

Ford uses Santoprene throughout the F-150, including for the headlight seals, air duct systems, glass encapsulation, and cowl seals. Further, the material comes in lighter, is fully recyclable and reduces energy consumption when parts are produced. So, not just weight savings are realized — there are clear energy and environmental benefits at work as well.

Part Reduction Initiative

You may have heard that cars are typically composed of more than 30,000 parts, including the smallest screws. No matter how well constructed a vehicle is, the more parts at play, the more likely something will break. And those failed parts cost consumers not just in expected maintenance and repairs, but in lost time. Moreover, manufacturers routinely must replace such parts when covered under warranty or through a recall.

capless fuel tank — The capless fuel system in the F-150 is possible because of DuPont (copyright Ford Motor Company).

Working in cooperation with the Ford Motor Company, DuPont Automotive has developed components to improve air management systems through extensive use of high-performance thermoplastics, composites, and elastomers. These materials replace metal and rubber components and have been credited with reducing weight by up to 50 percent, reducing costs by as much as 30 percent, while employing fewer parts.

One example of this part reduction initiative was achieved by using DuPont’s Zytel nylon in Ford’s 2.0-liter, four-cylinder EcoBoost engines. Replacing steel, the one-piece component comes in approximately 30 percent lighter than the two-piece steel assembly it replaced. It also has the side benefit of mitigating the air flow paths that contribute to turbo whine.

Further, a Zytel resin has replaced steel for the coolant crossover component found in the engine manifolds on Ford’s 3.5- and 3.7-liter V-6 engines. In this example, one pound was saved over the brazed metal it replaced. DuPont also supplies a thermoplastic polyester elastomer used in Ford transmissions and has contributed materials that have reduced noise, vibration, and harshness (NVH). The chemical giant has also made Ford’s capless fuel filler system a reality in many of its vehicles.

Sticky Business: Aluminum Bonding Adhesives

It should be made known that Ford makes use of high-strength, lightweight steel for the F-150’s frame and aluminum alloy for the front end, cab, box and the tailgate. Together, Ford achieves the desired weight savings and also manages to reduce spot welding.

Spot welding is extensively used in the auto industry, providing a way to weld the sheet metal to form a car. Typically a completely automated process, spot welding isn’t the best way to join materials. Instead, adhesives are.

Adhesive technology has progressed in recent years to where it is now an integral part of the automotive assembly process. In the Ford F-150, a Dow aluminum bonding adhesive called BETASEAL works as a glass bonding adhesive. Specifically, the Dow product serves as the windshield bonding material in this pickup truck.

Dow and Ford researchers have also been collaborating on developing automotive-grade carbon fiber and to establish component manufacturing methods for high-volume automotive applications. Ford is also working with such companies as Coca-Cola, Proctor and Gamble, and Heinz in bio-plastics and is cooperating with the Oak Ridge National Laboratory and Dow on carbon fiber.

Touring the Ford Rouge Factory

Taking a tour of the Ford Rouge Factory is perhaps the best way to visualize and understand the manufacturing process. The Ford tour runs from Monday through Saturday, except for holidays.

That tour begins with a brief film covering the history of the Rouge and then moves to another theater where special effects, including a 3D laser projection, are at work. The third leg brings you to the observation deck, an 80-foot-high enclosed platform where you will take in the full scope of the Rouge complex. Yes, that “living roof” below does manage millions of gallons of rainwater — and the birds love it.

The fourth part of the tour is the longest, one where you take in the entire build-out process for the F-150. Workers and robots handle various parts of the manufacturing process and you will get to see each part of the truck assembled. Line after line, and row after row, the front section, cab, truck bed and tailgate are assembled. I took special note of the windshield as it was fastened to each truck, understanding that the Dow BETASEAL product was the adhesive used.

The final leg of the Ford Rouge tour is where it ends — the Legacy Gallery. On display are five of the vehicles built at the plant, ranging from a 1929 Model A to a 1965 Mustang. These days, Ford Rouge handles F-150 production and nothing else.

Car Manufacturers and Industry Suppliers

Of course, the Ford Motor Company is not the only manufacturer finding ways to cut weight, an initiative the entire industry has embraced. Auto Trends has been tracking new models from Nissan, Chevrolet, and Toyota among others, and each one is using a variety of methods, including smaller engines to achieve these goals.

Other companies identified by the American Chemistry Council contributing to lightweighting through composites include SABIC, a supplier of thermoplastics in such Ford vehicles as the Fusion, Transit Connect, and the Lincoln MKT. Solvay is a maker of specialty polymers with its products found in electrical connectors, project headlight housings, and diesel fuel conditioning modules, to name a few. LyondellBasell provides interior and exterior components for the F-150, including front upper fascia, the front air dam, the rear tailgate appliqué, and fender flares.

Lower Fuel Prices Will Have No Effect on Big Three Innovation

December 9, 2014 by admin 1 Comment

GM, Ford and Chrysler Embrace Fuel Saving Innovation.

Fuel prices are continuing to fall, dropping below $2.50 per gallon for regular grade gasoline in some areas. That’s just the kind of move that has some shoppers looking at larger and less efficient vehicles, perhaps advancing certain auto trends not yet foreseen. The drop in fuel prices, expected to last for several years, won’t stop car manufacturers from innovating, however. Instead, there are a number of changes underfoot that will continue even if gas prices continue to trend downward.

Updated Engines for Chrysler

Ram 1500 innovation.

This small diesel powers select Ram 1500 models.

Of all the major manufacturers, the Chrysler Group has the heaviest exposure to larger vehicles. That’s good for profits, but it is bad in helping the company reach mandated corporate average fuel economy (CAFE) ratings. The problem becomes magnified in each succeeding year up to 2025, when manufacturers must find a way to produce and sell passenger vehicles averaging 54.5 miles per gallon.

Chrysler needs to move away from V-8 engines or at least offer powerful, smaller engines that can step in as well. At present it has a pair of V-6 engines that are likely to play a much larger role in helping Chrysler reach its goals. Specifically, Pentastar family engines displacing at 3.2 and 3.6 liters will receive important innovations.

Those upgrades will bring in a host of technologies such as turbocharging and direct injection notes AllPar.com. Ford makes use of these technologies in its EcoBoost engines, enabling it to provide smaller and more efficient engines with no loss in overall power. Currently, both Pentastar engines are naturally aspirated; making new technologies available will mean supplementing its current V-8 line of HEMI engines. Eventually, those larger engines might be dropped as the CAFE mandates are raised.

Continuously Variable Transmission for Ford

CVT innovation.

Toyota pairs its 1.8-liter engine with a CVT.

Just as Toyota added a continuously variable transmission (CVT) to the Corolla line beginning in 2014 and has enjoyed a nice boost in fuel economy, Ford may do likewise with some of its own models reports Automotive News. Much attention has been directed Ford’s way with the upcoming release of 9- and 10-speed transmissions. Those transmissions, however, will be paired with its larger engines.

A CVT could find its way in such cars as the Ford Focus and Fiesta. Certain versions of those models already get at least 40 mpg on the highway and a CVT could advance those numbers. CVT technology has been used by Nissan for more than 20 years, but other automakers have had mixed results, in part because of consumer hesitancy.

For instance, CVTs don’t use gear points as do standard automatic transmissions and cause a rubber band effect when pressing on the accelerator that returns a pulling sensation. Engines tend to sound louder and the resultant transmission lag annoys some people. Toyota has found a way to limit that sensation and that could be something Ford has figured out too.

GM Does Diesels

As gas prices fall, diesel prices drop too. Still, diesel fuel now carries a mark up of about 20 percent even as such engines are 30 to 35 percent more fuel efficient than comparable gas engines.

Chevrolet Cruze innovation

GM continues to use diesels in smaller vehicles including Cruze.

GM has long been committed to diesels with its heavy-duty pickup trucks. It also offers a diesel variant for the Chevrolet Cruze. Come 2015 and you will see an expanded diesel application in its midsize pickup trucks — Chevrolet Colorado and GMC Canyon. But it may not stop there.

Indeed, ever since the Ram 1500 received a 3.0-liter six cylinder diesel option, competing automakers have been studying doing likewise. GM, along with its Isuzu partner, jointly manage DMAX — a company that produces the 6.6-liter turbo diesel V-8 engine found in heavy-duty Chevrolet and GMC pickup trucks. A 2.8-liter turbo diesel four will power the midsize trucks; a 2.5-liter turbo diesel four is available in other markets, such as in Thailand.

What GM needs is a V-6 diesel motor and it once has access to one when it shared ownership of VM Motori with Fiat. In Oct. 2013, Fiat acquired GM’s 50 percent share in the company, effectively shutting GM out of the market. Still, GM likely has a V-6 turbo diesel on its drawing board, perhaps based on the smaller fours and measuring about 3.8 liters. Expect GM to green light production if diesel demand increases, but perhaps not until fuel prices are raised across the board again.

Big Three Innovation

Although engines and transmissions will play a significant role in improving fuel economy, further innovations will come through vehicle lightweighting. We’re seeing some of that right now in the aluminum-bodied 2015 Ford F-150. Ford’s competitors — domestic and foreign — are responding by choosing high-strength, but lighter weight steel, carbon fiber and are pursuing other fuel saving initiatives. These efforts will continue even as uel prices are sinking, what is likely to prove a temporary pull back as automakers prepare for much higher CAFE standards.

GM Pickup Truck Lightweighting to Follow Ford’s Lead

February 20, 2014 by admin 1 Comment

Next generation GMC and Chevrolet pickups will include more aluminum.

2014 Chevrolet Silverado High Country. — The Chevrolet Silverado may see a big weight
reduction in five years.

Fresh off of a new design, the next generation Chevrolet Silverado and GMC Sierra full-size pickup trucks wont hit the market for about another five years. When those trucks arrive, theyll likely include vast amounts of aluminum, following a path that the Ford Motor Company is taking beginning with the 2015 Ford F-150.

Aluminum Contracts Signed

The Wall Street Journal has reported that GM recently inked an agreement with two aluminum suppliers, Alcoa and Novelis, to supply the automaker with aluminum sheet for pickup trucks. It takes several years to align production with demand, giving GM enough time to secure the supply while it develops a new design.

GMs switch to aluminum is prompted by Fords move, what effectively gives its largest pickup truck competitor an edge in this highly competitive and lucrative segment. The automaker is also being pressured by federal regulators intent on raising fuel economy across the board including for pickup trucks. These trucks average about 20 mpg, but typically make just 15 mpg in combined city and highway driving.

Expanded Truck Line

Unlike Ford which has poured its entire resources into advancing its full-size truck line, GM has sought improvements in fuel economy by reintroducing a pair of medium-sized trucks: the Chevrolet Colorado and GMC Canyon. Both models hit the market this year as 2015 model year vehicles.

All three of the other truck manufacturers are also taking steps to make their trucks more efficient. For Fiat Chrysler Automobiles, the 2014 Ram 1500 now offers a 3.0-liter six cylinder diesel engine, the first manufacturer to offer such an engine in this class. That engine is rated at 28 mpg on the highway providing best-in-class fuel economy.

Nissan has reached an agreement with Cummins, Inc. to supply its next generation Titan pickup truck with a 5.0-liter V-8 engine. Cummins also supplies a 6.7-liter inline six cylinder engine for Rams heavy duty trucks, while Ford and GM super duty trucks take a similar approach. Reports have also indicated that Toyota may tap Cummins for the same diesel engine destined for the Titan for its own Tundra line.

Lightweighting Done Right

Vehicle lightweighting means that manufacturers are also able to go with smaller engines as they shed excess heft. The 2015 Ford F-150 loses about 700 pounds and will also offer a 2.7-liter V-6 engine, what previously was considered too small. The new engine is turbocharged and uses direct fuel injection, the same technology found in a 3.5-liter Ford V-6 engine on the market since 2011.

While Ford and GM compete for pickup truck sales, the two manufacturers are also collaborating on new 9- and 10-speed transmissions what will be used in a variety of vehicles including pickup trucks. The current collaboration builds on an earlier one where the companies jointly developed six-speed transmissions.

Raising large pickup truck mpg is an important step toward helping manufacturers meet a 54.5 mpg equivalent fuel economy average federal mandate for its fleet by the 2025 model year. That threshold was adopted in Aug. 2012. An assortment of alternative fuel vehicles including hybrids, electric vehicles, and hydrogen-powered models will help raise those averages, but improvements in pickup truck efficiency must also be realized. Lightweighting may yield the biggest savings up front with smaller engines and more efficient transmissions following.

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