I think the concerns of the aluminum body panels on the new F-150 is specific to this segment (trucks). Utility vehicles are expected to take more abuse. Gett

I think the concerns of the aluminum body panels on the new F-150 is specific to this segment (trucks). Utility vehicles are expected to take more abuse. Getting hit with tools/logs/ladders/etc. isn't uncommon and people are afraid their truck will look like a golf ball after a year. The main drawback of aluminum body panels is that it's difficult (i.e. expensive) to make them. I would imaging fatigue (from vibrations, for example) is also a larger problem in this application with aluminum than it is with steel. Citation on difficulties of fabrication (introduction paragraphs): http://www.thefabricator.com/article/stamping/warm-forming-of-alloys-in-the-auto-industry http://www.thefabricator.com/article/stamping/warm-forming-o... Additional considerations when designing dies for aluminum forming: http://www.schulergroup.com/major/us/technologien/produkte/aluminiumverarbeitung_systemanforderung_werkzeug/index.html http://www.schulergroup.com/major/us/technologien/produkte/a... A list of some cars using aluminum body panels: http://www.paintgages.com/List-of-Car-Manufacturers-who-use-Aluminum-Body-Panels-s/51.htm http://www.paintgages.com/List-of-Car-Manufacturers-who-use-...