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Jaguar: aluminum-intensive XE will feature fuel consumption lower than 4L/100km; structure is 75% aluminum

The aluminum body of the XE. Click to enlarge.

In the second of four technology previews leading up to the introduction of the new Jaguar XE on 8 September, Jaguar outlined its extensive use of aluminum in the new model. Designed around Jaguar’s modular vehicle architecture, the XE is the only car in the class to use an aluminum-intensive monocoque, with lightweight aluminum accounting for 75% of the structure.

The new aluminum-intensive SE will be paired with engines from the new Ingenium family of efficient diesel and gasoline engines (earlier post)—powertrains specifically designed and calibrated to complement reduced-weight vehicles. Jaguar projects that the resulting XE will achieve fuel consumption of less that 4.0 l/100 km (59 mpg US) on the NEDC combined cycle (subject to certification) and CO2 emissions of less than 100 g/km.

The Jaguar XE is also the first car to make use of a new grade of high-strength aluminum called RC 5754 which was developed specifically for the XE and can take up to 50% recycled content—making a significant contribution to Jaguar’s goal of using 75% recycled material by 2020. The high percentage of recycled content also reduces lifecycle emissions by requiring less electricity in production.

Lightweight construction is a core element of Jaguar’s DNA and Jaguar is at the fore of aluminum technology in the automotive industry. The Jaguar XJ, XK and F-Type have all been developed using exceptionally stiff bonded and riveted aluminum structures; now the XE becomes the latest model to use this technology, now in its fifth generation.

The Jaguar XE body uses over 75% aluminum content, which far exceeds any other car in its class. This gives us a body structure with unrivaled low weight: it’s light but also immensely strong with extremely high levels of torsional stiffness. We’ve made sure our aluminum-intensive body structure exceeds all global safety standards without compromising on vehicle design or refinement.

—Dr. Mark White, Jaguar’s Chief Technical Specialist; Body Complete

The structure also delivers exceptional torsional stiffness. The light but strong architecture incorporates highly advanced suspension systems delivering ride quality, handling and steering, Jaguar says.

Chassis technologies. In the first technology preview, Jaguar previewed some of the chassis technologies for the new XE, including its integral link rear suspension, unique to this segment.

The Integral Link suspension delivers benefits over conventional multi-link designs, Jaguar said. By providing lateral and longitudinal stiffness, the integral link delivers sharp response and handling while retaining a refined, luxurious ride.

Many components of the Integral Link suspension have been forged or hollow-cast in aluminum.

XE’s front suspension is based on that of an F-TYPE sports car. Mounted to a subframe with cast aluminum suspension towers, the XE’s double wishbone front suspension delivers high levels of handling and road-holding, according to the company.

The advanced design includes some key components designed to deliver Jaguar XFR-levels of stiffness. These ensure the XE enjoys a similar level of agility and connected steering feel. Like the rear suspension, many components are made from cast and forged aluminum and some are produced using a patented process.

XE will also become the first Jaguar to be equipped with the latest generation Electric Power Assisted Steering. The new software algorithms now allow much greater scope for tuning than hydraulic-based systems and deliver better quality steering feel. Other benefits include variable steering damping, ease of low-speed maneuvering and the ability to adapt to Jaguar Drive Control settings. EPAS also enables a range of Active Safety and Driver Aid features.

Jaguar has also developed All Surface Progress Control, a new feature in its class. ASPC works like a low-speed cruise control to deliver optimum traction in the most slippery conditions without skidding and without the driver using the pedals.

Click to enlarge.

Designed and engineered in the UK, the XE will be the first Jaguar to be manufactured at a new purpose-built production facility at the company's Solihull plant in the West Midlands in the UK.



Way to go Jaquar! Less dead weight = an XE @ 60 mpg.

When ALL others do it, the US fleet could go from 23 mpg to 69+ mpg?

This is also one of the best way to go for future (500+ Km) Extended range BEVs?


Tesla uses aluminum, Audi has used it on and off for years. It is a matter of markets and costs. It costs more to make a car with an aluminum chassis, if the customer is willing to pay for that, they might do it.

This points to the idea that only high end cars that can absorb the cost will be the first candidates. Now, if the high end customer cares about an extra 2 mpg, that is the question. I think it will become the norm in high end cars to reduce the weight, but still be safe.


(High end) Ford F-150 (2015) will board the train?


It remains to be seen what F150 sales will be in 2015 and at what price. F150 is a popular model with lots of sales, will the increased mileage make up for the increase in price?


The 2015 Ford F-150 will start at $26,615, around $400 more than the 2014 model. High-end models will jump by as much as $3,500. (Ford Motor Co.)


Another difference is the F150 still uses a steel frame, only body parts are aluminum. The Jaguar XE uses an aluminum unibody design. I don't consider the F150 to be in the same design category as the Jaguar XE.


It is a very good first step towards a much lighter F-150 at about the same price?


Another difference is the F150 still uses a steel frame, only body parts are aluminum.

F-150 is a body-on-frame design, so it's a bit more than that.. Basically, everything that would be aluminum in a typical unibody car is aluminum in the F-150: the passenger cell, the 'trunk', etc.


Ford sells 700,000 F150 trucks per year in the U.S. they expect sales to fall 90,000 units in 2015. $400 extra does not seem like much, but few buy the basic truck, the high end trucks are $3500 more, that is where the volume is with the V6 ecoboost engines.

Truck buyers may not accept an aluminum frame on a truck, but the might also question aluminum on body panels and bed. Dents and scratches, corrosion will all be issues to the new buyer.


I don't see the distinction. Steel ladder frame with aluminum panels for cab and bed is NOT the same thing as an all aluminum chassis.


The real distinction is that the F150 in aluminum will provide a real reduction in oil consuption.

The Jaguar XE will provide no noticable reduction.
(Unless they sell 610,000 of them.)

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