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Fuel economy regulations are driving all OEMS to reduce vehicle weight as one means to meet the 2025CAFE target of 25.5 mpg (4.35 l/100 km). Ford Motor Company redesigned their most successful model, the F-150 Pick-up, drastically to an all-aluminum body saving approximately 700 pounds in total body weight. The paper will elaborate on the transition from a metal substrate mix to an all-aluminum body and the transition from a traditional standard zinc phosphate, to a flex or 2-Step process and finally a zirconium pretreatment technology.

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