It's no secret that lightweighting is one of the hotbeds of the U.S. automotive industry. As the government's aggressive 2017-2025 fuel economy regulations come to pass, automakers are looking to cut weight from vehicles as much as possible without sacrificing safety and performance.
TROY, MI- It's no secret that lightweighting is one of the hotbeds of the U.S. automotive industry.
As the government's aggressive 2017-2025 fuel economy regulations come to pass, automakers are looking to cut weight from vehicles as much as possible without sacrificing safety and performance.
In an attempt to find feasible solutions for the future, Magna International Inc. and Ford Motor Co. have partnered on a "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 big highlight is the usage of different materials," said Magna Chief Technology Officer Swamy Kotagiri during the supplier's 2014 "Innovation Day" on Tuesday.
The vehicle includes numerous advanced materials, including strategic applications of aluminum, ultra-high-strength steels, magnesium and carbon fiber. The carbon fiber and magnesium are used sparingly to keep costs down. It also features advanced glass similar to the kind used in smartphones.
In total, the research vehicle weighs 24 percent less than the production Fusion. At roughly 2,635 pounds, the midsize sedan research vehicle weighs roughly the same as a Fiesta subcompact sedan with automatic transmission.
The "Lightweight Concept" vehicle from Magna International Inc. and Ford Motor Co. at the supplier's 2014 "Innovation Day" on June 10, 2014. Research for the vehicle – based on the 2013 Ford Fusion – began two and a half years ago and is expected to continue through this year with production and testing of seven prototypes. David A. Wagner, Ford technical leader of vehicle design research and advanced engineering, said the company has built three prototypes already.
"All of this is we have to give our customers the right value," he said. "Vehicles at the right size with the right capability at the right price point that of course keeps them safe and durable."
The research vehicle was developed with the U.S. Department of Energy's Vehicle Technologies Program to illustrate long-term potential light-weighting solutions.
Wagner said development of its nearly all-aluminum 2015 F-150 also helped with the program. With its more than 95 percent aluminum body and new high-strength steel chassis, the 2015 F-150 is up to 700 pounds lighter than the outgoing model.
"We learned a lot from the F-150 for this," Wagner said. "This really builds on what Ford's message."
Reduction in vehicle weight, according to officials, also led to other fuel economy improvements. Although the Lightweight Concept focused on reducing weight, one of the vehicles also features a 1.0-liter Ecoboost engine traditionally reserved for small cars.
Officials said final fuel economy numbers and cost of the prototype vehicle are expected by the end of the year.
Michael Wayland covers the automotive industry for MLive. Email him at MWayland@mlive.com & follow him on Twitter @MikeWayland or Google+.