The automaker has teamed with Alcoa to commercialize the supplier’s new ‘Micromill’ technology, used to create aluminum sheet that is claimed to bring 40 percent greater formability and 30 percent greater strength than current alternatives.
As the name implies, the advancement is billed as a milling breakthrough rather than an entirely new alloy, though it could be used to produce next-generation alloys. Alcoa suggests molten metal can transition to production-ready coil in just 20 minutes, compared to a weeks-long process at some traditional rolling mills.
Perhaps more importantly for automakers, the metal’s unique crystal structure can reportedly be stamped into complex shapes, such as the inside of door panels, that previously required steel sheet. Strength improvement equates to better dent resistance for thinner sheet, allowing vehicles to shed even more weight.
“We believe the technology can be used to develop new alloys that will improve our ability to form complex parts, which will help in both design and efficiency,” said Ford’s structures and stamping manager, Peter Friedman.
Ford will begin using Micromill aluminum later this year for a few parts in the 2016 F-150, with plans to expand its use to new vehicle platforms in the coming years. The company did not mention which pickup parts will be made from the technology, or if the 2016-model-year pickup will shed even more weight than the 2015 edition.
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