Aluminum repair more expensive than steel on vehicles

There's always economy of scale. Steel is cheap because of the massive scale in which it's produced. Last I checked (A long long time ago), the US is the world's top manufacturer of Aluminum. Maybe we'd see more mines start up to sell the material? Then as repairs become more common-place, they'd get cheaper. How much cheaper? I have no idea, but I'm sure there's something to be gained with economies of scale. Interesting statement by Ford though that they're concentrating their aluminum efforts only on the pickups, leaving the cars steel for now. Maybe there just isn't as much opportunity with cars given the advances of AHSS.

http://www.mapsofworld.com/minerals/world-aluminium-producers.html

FYI

If you include how aluminum does not rot on old vehicles repairs should be cheaper once they get older. I doubt insurance companies will remember to recognize that.

jus2shy wrote:
There's always economy of scale. Steel is cheap because of the massive scale in which it's produced. Last I checked (A long long time ago), the US is the world's top manufacturer of Aluminum. Maybe we'd see more mines start up to sell the material? Then as repairs become more common-place, they'd get cheaper. How much cheaper? I have no idea, but I'm sure there's something to be gained with economies of scale.

It's an absolutely pipe dream to think that anything will ever get less expensive. From the perspective of: today it costs 75% more than steel but tomorrrow it will only cost 60% more than steel (once it becomes more common), then while it gets cheaper, it's still more costly. The trend in the last 15 years is that all vehicle cost have shot up dramatically, many times exceeding the rate of inflation by significant margins. In my lifetime, I've never seen anything related to the transportation world decrease in cost (except the fluctuations due to oil prices). As these general costs increase, so the do the associated costs like insurance, taxes, etc.

Just another prime example of an over-reaching government that causes hardships on the people with their regulations.

from a ford site
-2014 part #FL32-9527840-A =$967.48
-2015 part#AL328427840-B =$968.48

box side replacement part

GM silverado is a bit less,they pick the price they want I bet.
Labour depends on where you are.

horton333 wrote:
If you include how aluminum does not rot on old vehicles repairs should be cheaper once they get older. I doubt insurance companies will remember to recognize that.

Have you seem what happens to aluminum when it comes into contact with steel? It is not pretty. Be interesting to see how this all shakes out in a few years.

Mopar_Mudder wrote:

horton333 wrote:
If you include how aluminum does not rot on old vehicles repairs should be cheaper once they get older. I doubt insurance companies will remember to recognize that.

Have you seem what happens to aluminum when it comes into contact with steel? It is not pretty. Be interesting to see how this all shakes out in a few years.

They have been building airplanes of aluminum for over 50 years. I think they have pretty much "shaken out" everything by now. Your Mopar is going to be made out of aluminum some day soon. The recent federal regs have guaranteed that.

wing_zealot wrote:

Mopar_Mudder wrote:

horton333 wrote:
If you include how aluminum does not rot on old vehicles repairs should be cheaper once they get older. I doubt insurance companies will remember to recognize that.

Have you seem what happens to aluminum when it comes into contact with steel? It is not pretty. Be interesting to see how this all shakes out in a few years.

They have been building airplanes of aluminum for over 50 years. I think they have pretty much "shaken out" everything by now. Your Mopar is going to be made out of aluminum some day soon. The recent federal regs have guaranteed that.

I don't have a problem with it, if it is done correct it is a good thing. An airplane is a far cry from a mass produced vehicle. No alum will not rust, but it can corrode when conditions are right.

Aluminum and steel in a marine enviroment (salt water) is a no brainer ,the solutions are many and no mystery.The dutch have been building steel hulled aluminum superstructures since the 60's and the U.S. navy also .
Galvanic corrosion is easily dealt with(active and passive) , just plain aluminum oxidizes to a incredibily tough surface that protects the metal under neath,compare to steel ,it will oxidize continuously until all the iron is gone.

Designers of airplanes vs automotive are of different class of designers

Plus they have to understand and deal with 'air planes falling out of the sky'
issues within their designs and down stream...mainly maintenance...that
automotive designers NEVER have to deal with

DITTO longevity...air planes are kept in service for decades vs just
a few years for automotive (except for semi's and the like)

Not to say air plane designers don't screw up...they do

The only reason for aluminum in automotive is weight savings. All or
all that I know of, end up being compromises in reference to steel

ALU does naturally self heal with an oxide that is one of the hardest
materials known (sandpaper employs it as the grit)...but it is easily
attacked by chemicals like salt and scarficial to most other metals

There are three main metals used as galvanic anodes: magnesium,
aluminium and zinc. Why mixing ALU in contact with iron/steel is a
very bad design flaw

Current leader in Alu body IP is Audi and take note that they are
made up of both STEEL and ALUMINUM for the monocoque. No direct contact
between steel and aluminum because they have proprietary glued (epoxy
and other cool stuff) together joints...but....few know that epoxy
never stops 'curing'...AKA getting harder and more brittle

Anyone know how Ford managed this on their pickups?....all it takes
is ONE steel screw to get it's plating scratched/etc to then start
rotting out the ALU