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Ford went to aluminum for one reason and one reason only: to lower its fleet fuel economy figures to meet EPA standards. They didn't do it because it was better for the consumer, they did it because it was better for the corporation. It's evidently going to cost more to repair body damage now, and anybody who knows anything about metallurgy would have predicted that. Who does more costly repairs benefit? If it's more costly to repair, it'll be more costly to insure. Who benefits? Ford and the insurance companies. Who pays? The consumer.
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Car and Driver article:
In-Depth with the 2015 Ford F-150's Aluminum, With an Alloy of Facts and Perspective
"On a per-pound basis, aluminum costs roughly twice as much... The bottom line, or at least the intended one, is lighter and more fuel-efficient pickup trucks. Comparing the curb weight of an F-150 we tested five years ago with the 2015 edition reveals a net weight savings of about 300 pounds. Unfortunately, the validity of such comparisons are undermined by the move to smaller and lighter engines, more lavish creature comforts, and ever-rising haul and tow ratings."
