Sure, aluminum bodies/frames would theoretically reduce weight, but, for starters, aluminum is not as dense or strong as steel in the same thickness. A car’s body and chassis make up over 50% of the average car's weight. Material can definitely make a big difference in weight, stiffness and strength of the car. The tensile strength of steel is about four times stronger than the strongest aluminum alloys available.
The tensile strength difference means that aluminum parts need to increase thickness to meet safety standards. Of course, the thicker aluminum parts may still come out lighter than their steel counterparts, but the thicker aluminum is more expensive in manufacturing than steel. The cost of aluminum materials is about two to three times higher per pound than steel.
It would be great if Ford built a hi-po Mustang making 500+ hp with a curb weight of less than 3500 lbs., but it would be costly, for sure. And for whatever reason, Ford isn’t interested. Nor is any other major auto maker in the U.S.
The tensile strength difference means that aluminum parts need to increase thickness to meet safety standards. Of course, the thicker aluminum parts may still come out lighter than their steel counterparts, but the thicker aluminum is more expensive in manufacturing than steel. The cost of aluminum materials is about two to three times higher per pound than steel.
It would be great if Ford built a hi-po Mustang making 500+ hp with a curb weight of less than 3500 lbs., but it would be costly, for sure. And for whatever reason, Ford isn’t interested. Nor is any other major auto maker in the U.S.
