Page 2 - Mortor Fan illustrated

ALUMINUM Smart Developments

Case Study The impact of the application of aluminum

01 01 FORD F-150

Steel has traditionally been the major material used for Regarding the materials used for automobile bodies, there are when will this trend take off with mass-produced vehicles? The the door panels. Which part will be next? “The roof”, was
automobile construction. However, in order to meet today’s four major trends: all-aluminum; full use of steel, such as impact on general consumers of the all-aluminum body structure Niikura’s reply. “To apply aluminum to the roof, it’s essential to
severe fuel efficiency requirements, the application of other ultra-high tensile strength steel; a hybrid of steel and aluminum; F-150 has been considerable. The fact that such a representative change the outer side panels to aluminum, and that requires the
materials is progressing to replace steel. UACJ R&D Division and multi-material (steel, aluminum and CFRP), which is currently North American vehicle adopted aluminum created powerful development of aluminum alloys with better formability. For
General Manager Akio Niikura talked to us about the ways becoming popular. images of ‘Aluminum is cool’ and ‘Aluminum is more advanced’. aluminum manufacturers, the aluminum roof is the ultimate goal.”
aluminum is now being applied to automobiles. This has provided a major impetus for switching to aluminum. It’s
Switching to an all-aluminum body structure is progressing in estimated that the volume of aluminum body sheets used for a Akio Niikura, Ph.D.
The weight of automobiles affects cruising distance, so the main North America. The Ford F-150 took the initiative in this vehicle in North America will dramatically increase by about 10
merit of using aluminum for automobiles is its effect on vehicle movement. The use of aluminum for large pick-up trucks has had times, from 6.3kg in 2012 to 61kg in 2025. General Manager,
Development Department II & III,
weight reduction. Aluminum is excellent in terms of strength and outstanding weight reduction results: in the case of the F-150, the Research & Development Division,
ductility, but it cannot match steel in ease of forming because of total vehicle weight was reduced by about 320 kilograms. The The flow of switching to aluminum body panels began with the UACJ Corporation
its inferiority in elongation and shape-freezing properties. switch to aluminum began with the larger and luxury vehicles, but bonnet, extended to the trunk lid and back door, and then over to

Small overlap test Motor Fan illustrated
FORD F-150
Motor Fan illustrated
Motor Fan illustrated
Motor Fan illustrated
Small overlap frontal crash tests are
conducted by the Institute for Highway Safety
(IIHS). In the test, 25% of a vehicle’s front end
on the driver’s side strikes a rigid barrier at
40mph (64kph). The overlap percentage is ALUMINUM Smart Developments
much lower than in a conventional 40% off-set
crash, which means the strength required for
the cabin becomes greater.
ALUMINUM Smart Developments
ALUMINUM Smart Developments
ALUMINUM Smart Developments
In all the crash tests, including small overlap
tests, the Ford F-150 has been evaluated as
02 GOOD, the highest score. 03

The issue of aluminum recyclability Region Approach

Aluminum alloys feature high recyclability but recycled rolled materials become Long-term target for required fuel
castings which are now often used for parts like engine cylinder blocks. As the Europe efficiency: CO 2 emissions of
change from internal combustion engines to electric motors intensifies, which 95g/km by 2021
parts recycled aluminum alloys can be used for will become an important issue.
Newly introduced fuel-efficiency
Impact of the Ford F-150 standards to be reached by
North 2025: fuel-efficiency of 54.5
The F-150 is the best-selling vehicle in North America and the core America mpg (23.2km/ℓ) for passenger
cars and small trucks; CO 2
model of the Ford F-Series of pickup trucks. The complete model emissions up to 143g/mi
change conducted in 2014, with a new steel frame clad in (89g/km) for passenger cars
aluminum body panels, attracted a lot of attention in the market.
The use of aluminum alloys for the cabin and the cargo area
reduced the weight by about 230 kilograms. The reduction in the Target fuel efficiency: 20.3km/ℓ
total body weight of about 320 kilograms improved fuel efficiency Japan (JC08 Mode) for gasoline-powered
by up to 20% compared to previous models. passenger cars by 2020

PHOTO: FORD