Ford builds on advanced materials use with lightweight concept car

Ford has unveiled its Lightweight Concept vehicle, which uses advanced materials to explore future weight-reduction solutions that could improve performance and fuel efficiency while reducing carbon dioxide emissions.

The company says the vehicle represents the latest phase of Ford’s research into developing sustainable technology solutions that are affordable for consumers and can be produced in large volumes across the product line-up. This research has also led to weight reductions of up to 700 pounds in the all-new F-150. The 2015 F-150 sheds weight through the use of high-strength steel and aluminium, enabling it to tow more, haul more, accelerate quicker and stop shorter – all with improved fuel efficiency.

“Consumers today want better fuel efficiency, but they also want more technology and features in the car, which usually adds weight to the vehicle,” said Raj Nair, Ford group vice-president, Global Product Development. “A focus on lightweighting will be fundamental to our industry for years to come, and we are investigating many advanced materials applications as possible solutions for weight reduction in our vehicles.”

Ford’s research into improved efficiency through weight reduction with advanced materials including new metals, alloys and composites began more than 25 years ago. This research produced the breakthrough Aluminium Intensive Vehicle program in 1992 and all-aluminium high-performance Ford GT in 2005.

Holistic approach to lightweighting
Ford’s Lightweight Concept uses many of the same advanced materials found in today’s lightweight electronic devices, including aluminium, chemically toughened glass and advanced lightweight plastics.

Ford engineers took a holistic approach to weight reduction by incorporating advanced materials into the entire design of the vehicle, including powertrain, chassis, body, battery and interior features such as seats. This Lightweight Concept vehicle represents its most comprehensive blend of advanced materials yet in one vehicle, including strategic application of aluminium, ultra-high-strength steels, magnesium and carbon fibre.

The research vehicle was developed with the US Department of Energy’s Vehicle Technologies Program, together with Cosma International – a subsidiary of Magna International – to illustrate long-term potential lightweighting solutions. Magna’s design and development of the multi-material body-in-white, closures and chassis components are a significant contribution in lightweighting the concept vehicle.

“Our goal was to investigate how to design and build a mixed-materials, lightweight vehicle that could potentially be produced in high volume, while providing the same level of safety, durability and toughness as our vehicles on the road today,” said Matt Zaluzec, Ford technical leader, Global Materials and Manufacturing Research. “There’s not a one-size-fits-all approach to light-weighting. The Lightweight Concept gives us the platform to continue to explore the right mix of materials and applications for future vehicles.”

Other industries have incorporated lighter-weight advanced materials to achieve greater fuel economy, speed and performance. Aviation and aerospace industries – commercial and military – make extensive use of composites structures and mixed materials, including aluminium and carbon fibre, to reduce weight and maximize fuel efficiency. The rail industry makes extensive use of lightweight materials to reduce weight in high-speed and bullet trains. The heavy truck transportation industry uses lightweight materials including aluminium and high-strength steel to improve fuel efficiency.