That car is the Ford GT – the legendary Ford GT, redesigned, re-engineered and re-launched for the 21st Century. Aluminum extrusions from Hydro Aluminum are key elements of this exciting new vehicle.
Aluminum was chosen for its strength, light weight and cost effectiveness. It fit both the price point and the high-tech image that Ford wanted for the car.
All-aluminum chassis
The new Ford GT features an all-aluminum chassis, something unheard of in the 1960s when the car was first produced. Hydro extrusions connect four corner castings and one behind the passenger compartment to create a welded frame that is lightweight, yet rigid and strong.
“The frame needs to be light so that the GT can achieve its performance targets,” said Jim Brown, Sales Manager, Hydro Aluminum Transportation Components, and a leading member of the Ford/Hydro team. “Yet it must have the stiffness required by the high-tech suspension system. Aluminum meets these objectives. And the cost is highly competitive.”
Hydro is supplying 35 individual extrusion profiles for the GT. Thirty of these were developed specifically for Ford. In addition to chassis and rocker panel extrusions, bolt-on extrusions add structural support to the engine compartment and are also integrated into the bumper assembly. In a low impact crash, damaged bumper extrusions can be easily unbolted and replacements bolted on. The rear sport bar is also a Hydro supplied extrusion.
A close partnership
The unique extrusion designs were worked out in close collaboration with the Ford GT team. Hydro worked side-by-side with Ford designers and engineers to advise them on the feasibility of each specified extrusion and how well it would meet structural and performance objectives. Ford engineers were highly appreciative of Hydro’s input, response and flexibility.
“We sat in on almost every meeting that Ford had concerning the frame,” said Brown. “There was a lot of back and forth discussion.”
With their expertise in extrusion technology, Hydro engineers were able to analyze the specs for each extrusion and recommend any required modifications.
“Our die-making skills are among the best in the industry,” said Lance Auyer, Business Development Manager, Hydro Aluminum Transportation Components. “As Ford fine-tuned the design for the GT, and the shape or thickness of profiles changed, we were able to create new extrusion dies with little problem.”
Advanced production techniques
The GT is not only a high-tech vehicle, it is assembled using advanced, high-tech production techniques. Robotic welding and friction stir welding are used throughout. The extrusions had to be able to withstand the heat of welding, and this figured into their design. Jim Brown was part of Hydro’s welding team.
“One advantage of extrusions is that the thickness of the walls can be varied,” said Brown. “Our group was able to advise Ford on the proper thickness needed at the welding points to ensure perfect welds.”
The right alloys
Two types of aluminum alloys are used in the GT extrusions – 6061, where strength and the ability to endure intense welding are most important; and 6063, where weight and design are more of a factor. The 6063 alloy was also selected for use in the bumper assembly because of its ability to absorb impact.
“We’re able to provide our customers with the full range of alloys,” said Auyer. “As a result, each GT extrusion has the precise performance characteristics for its specific use.”
Extensive automotive experience
Ford selected Hydro Aluminum because of the company’s automotive experience. Hydro had previously partnered with Ford on the TH!NK Neighbor zero-emissions, golf-cart style electric vehicle. Hydro produced the aluminum frame assembly and “greenhouse” components. And Ford’s Jaguar/Aston-Martin division in Europe had worked with Hydro Aluminum's business centers in Europe.
Record time-to-market
With over 500 horsepower, the Ford GT is not only fast; it was brought to market in record time.
“It was only 12 months from the initial design until Ford produced the three prototypes featured at the Centennial celebration,” said Auyer. “Ford was on a very fast track, and the fact that extrusions can be easily modified as a design is fine tuned helped keep them on schedule.”
The 2005 Ford GT went on sale to the public in spring 2004. Ford will build approximately 1,500 of the supercars a year. If you’re lucky enough to buy one, or see one standing still, check out the door handle. It’s one of the aluminum frame extrusions serving a dual purpose. Every time you open the door, you’ll get a feel for the high-tech metal that plays such an important role in this historic vehicle.
