Ford Motor Company aluminum-intensive vehicles use various alloys to provide the desired crashworthiness, dent resistance and manufacturability. The properties of aluminum structures have been extensively tested in the lab. Based on this testing, company researchers developed very accurate computer test models, which allow them to precisely predict the performance of aluminum components under impact loads. These models were compared against actual crash tests and were able to predict the rate and order at which structural components would collapse to absorb energy. These tools will provide a key advantage in future construction of aluminum vehicle structures, allowing engineers to design aluminum components from a safety perspective - just as they currently do with steel.
Further refinement is needed to develop mass-production assembly techniques for aluminum vehicles.
Virtually all aluminum vehicle construction so far has been relatively low-volume. Some efforts have used techniques such as space-frame construction that are not conducive to mass production. Since aluminum's greatest potential lies in reducing the weight of mass-produced, commercially viable vehicles, continuing research is focusing on improving manufacturing and assembly techniques. Aluminum test vehicles have driven millions of miles since 1994. Crash testing proves aluminum has the potential to be a safe material for vehicle bodies, frames and structural members.