Is Ford Fusion aluminum?
The Ford Fusion is not aluminum throughout; it is built primarily from steel, with only limited use of aluminum components in some generations or trims.
To understand this question in more detail, we look at how the Fusion’s body was constructed across its production years, whether Ford used aluminum in any panels, and how this choice compares to Ford’s aluminum-intensive models such as the F-150. The Fusion’s production ended after the 2020 model year, so material choices are primarily a historical look at a specific era of Ford’s design philosophy.
Material makeup of the Fusion across generations
Across its 2006 to 2020 run, the Fusion’s body structure was built largely from conventional steel, including high-strength variants in key safety and crash areas. While Ford has pursued aluminum in some models to save weight, the Fusion was not marketed as an aluminum-heavy vehicle. Any aluminum use in the Fusion has been minimal and not a defining feature of the model line.
Comparison with Ford's aluminum-intensive models
The contrast with Ford’s best-known aluminum program is stark. The F-150, introduced as aluminum-intensive in the mid-2010s, used aluminum extensively to reduce weight and improve fuel economy and payload. By comparison, the Fusion did not adopt a similar aluminum-centric approach, and its weight-saving efforts relied more on steel engineering—such as optimizing structure and harnessing high-strength steel—than on widespread aluminum parts.
What this means for owners and buyers
For prospective buyers and owners, the material makeup of the Fusion means typical maintenance and repair involve steel-body components, with standard corrosion protection and repair practices consistent with mid-size sedans of its era. The absence of a broad aluminum footprint also means familiar repair processes and aftermarket parts availability remained in line with other non-aluminum sedans in its class.
Summary
In short, the Ford Fusion is not an aluminum-heavy vehicle. It relies on steel for most of its body structure, with only limited use of aluminum components, if any, depending on the year and trim. This stands in contrast to Ford’s F-150, which embraced aluminum more comprehensively for weight reduction. The Fusion’s material strategy reflects mainstream mid-size sedans of its time, and the model was discontinued after 2020, leaving a history of steel-focused construction rather than an aluminum-centric design.
Does the Ford Fusion have an aluminum body?
The body is comprised of high-strength steel and extruded aluminum. Composite materials for the front springs, an aluminum subframe, and hollow steel springs for the back comprise the suspension.
Which Ford models are aluminum?
Ford vehicles with aluminum bodies include the F-150 since the 2015 model year and the F-Series Super Duty trucks (F-250, F-350, etc.) since the 2017 model year. These models use military-grade, high-strength aluminum alloy for the body panels and bed, which reduces weight while maintaining or increasing strength and durability compared to previous steel versions.
- Ford F-150: The switch to an aluminum body began with the 2015 model year redesign.
- Ford F-Series Super Duty: These trucks, which include models like the F-250 and F-350, adopted aluminum bodies starting in 2017.
- Benefits of aluminum: The lighter material allows for improvements in fuel economy, towing capacity, payload capacity, and overall performance. It also offers enhanced durability and resistance to corrosion.
- Construction note: It's important to remember that while the body and bed are aluminum, the frame of these trucks is still made of high-strength steel.
Are Ford engines aluminum?
The Ford GAA engine is an American all-aluminum 32-valve DOHC 60-degree gasoline-fueled liquid-cooled V8 internal combustion engine with a flat-plane crank.
What is the body material of the Ford Fusion?
Body Structure of Ford Fusion (source: [1]) Hot-formed steels, also called “Boron steels” or Ultra-High Strength Steels-UHSS, offer a great weight saving potential versus conventional cold-formed high strength steels used for crash relevant structural parts.
