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NEWS
Ford's feather-weight Fusion
Materials tech in Ford's Fusion based lightweight concept yields 25 per cent weight reductionThe car pictured here is a lightweight concept based on Ford's Fusion, the car we will come to know as the next generation of Mondeo.
While it retains the packaging of the mid-size Fusion, the lightweight concept weighs as little as a Fiesta – a hatchback two classes smaller. Ford engineers, working in unison with researchers at the US Department of Energy and Cosma International, claim to have lowered the weight of the car by nearly 25 per cent.
Much of the inspiration for the concept passenger car came from the new F-150 commercial vehicle, which has adopted high-strength steel and aluminium alloys throughout for a weight reduction of up to 700 pounds (318kg).
"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 light-weighting 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."
The Lightweight Concept builds on the F-150's weight reduction strategy with new materials technology like chemically toughened glass, carbon-fibre and magnesium as examples. Underpinning the whole concept was the prospect for the new technology to make it to production.
"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."
The Lightweight Concept features the 1.0-litre three-cylinder EcoBoost, which should have little trouble powering a car that weighs about the same as a Fiesta. Ford claims that the small-displacement engine shaved 24 per cent off the weight of the powertrain, and weight-saving measures include hollow steel crankshafts, forged aluminium connecting rods, a carbon-fibre oil pan, front cover and cam carrier, plus cast aluminium and magnesium transmission components.
Underpinnings are 30 per cent lighter and deliver fuel efficiency gains by means of narrower tyres, 19-inch carbon-fibre wheels, aluminium brake rotors coated in steel, composite and hollow steel springs and hollow steel anti-roll bars, Ford claims.
In the cabin, the seats are constructed from carbon-fibre and interior trim materials included foamed plastic. The combination of a polycarbonate rear window and a hybrid sandwich of chemically toughened glass bonded to soda lime glass for the side windows and windscreen yielded a 35 per cent weight saving.
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Written byCarsales Staff
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