1) Aluminum use in vehicles has grown steadily over the past 40 years from 100 lbs per vehicle in 1975 to over 300 lbs currently, and is projected to reach 550 lbs by 2025.
2) Past growth has been led by powertrain and wheel applications, but future growth is expected in body, closure, and bumper components.
3) Using more aluminum allows automakers to reduce vehicle weight to meet fuel economy standards in a cost-effective way while maintaining safety and performance.
4) Continued growth of aluminum is expected as automakers and consumers demand lighter, more fuel efficient vehicles.
2. 40 Years of Uninterrupted Growth
600 2025: 550 lbs
Pounds per Vehicle
500 2012: 343 lbs
400
300
200
100
0
1975 1985 1995 2005 2015 2025
The trend line continues to be
supported by new aluminum applications
Source: Ducker Worldwide 2011
AluminumInTransportation.org
3. Powertrain & Wheels Led Past Growth
Wheels 790
Transmissions 785
Cylinder Blocks 636
Cylinder Heads 588
Heat Transfer 516
Other Engine 371
Brake Parts 130
Closures 126
Steering Knuckles 115
Intake Manifolds 112
Control Arms & Links 89
Transfer Cases 88
Bumpers 70
Differential Carriers 69
Other Steering 60
Engine Mounts 49
Cradles & Crossmembers 24
IP Structure 23
Drive Shafts & Yokes 14
All Other Compnents 125
Millions of Pounds
Source: Ducker Worldwide 2011
AluminumInTransportation.org
4. Aluminum Hoods, Trunks, Doors
and Bumpers are Next
25
20
Pounds per Vehicle
11
Pounds per Vehicle New Applications 8
15 (Primarily body, bumper
& closure components)
4
10
12 1 11 12
10 10
5 6 8
5
3 2 3
0
2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015
Source: Ducker Worldwide 2011
AluminumInTransportation.org
5. Europe on a Similar Path
Source: Ducker Worldwide 2012
AluminumInTransportation.org
6. Aluminum Helps Automakers
Aluminum is the one material that
Audi relies on aluminum…
to achieve benefits of down
automotive industry professionals
weighting as seen in the 2011
rated as most helpful in meeting A8, such as a 25% increase in
the new CAFE fuel economy body stiffness, while reducing
standards… weight by up to 20%.
2011 WardsAuto/DuPont Survey Audi/ATG joint press release
of Auto Industry Challenges
Based on our current understanding, we
believe we’re approaching the practical
Plans to use more aluminum
limits of the application of high-
to cut vehicle weight.
strength steels [in vehicle bodies]…
BMW, Reuters Frank Paluch, Senior Vice President,
Honda R&D Americas
AluminumInTransportation.org
8. Aluminum Is Fuel Efficient
Matching smart design with
powertrain advances and
intensive use of aluminum
Vehicles downweighted
reduces weight to use less fuel
with aluminum can save or battery power.
fuel, thus saving
consumers money
at the pump A 5 to 7 percent fuel savings can
be realized for every 10 percent
weight reduction by substituting
lightweight aluminum for a
heavier material.
AluminumInTransportation.org
9. Aluminum Is Sustainable
Aluminum has
lower life cycle
CO2 emissions
than steel or high
strength steel
Source: Magnesium Front End Research and Development Project
AluminumInTransportation.org
10. Aluminum Is Safe & Durable
Safety Increased with Weight Reduction
ELU Scenarios
100 27%
28%
85.9
Downweighting is 80
necessary to meet 63.0 61.8
demands without 60
Other Car
ELU
sacrificing safety 40
Driver
or functionality
20
0
Baseline Added Length Reduced Weight
Baseline Weight Baseline Length
Adding crush space without adding
weight improves safety 27%
Source: Dynamic Research, Inc. (DRI)
AluminumInTransportation.org
12. Aluminum Is High Performing
Cars made lighter with
aluminum can
accelerate faster
and brake quicker
than their heavier
counterparts
Acura NSX Mercedes Benz SL
Jaguar XJ
Audi A8
AluminumInTransportation.org
13. Lighter vehicles
are less Aluminum Is Cost Effective
expensive for Secondary Weight Savings Adds Value
consumers to (Mass and Cost Savings by Component)
own and operate
Secondary
Source: IBIS Associates
AluminumInTransportation.org
14. Aluminum Is Cost Effective
Downweighting: Cost Benefit of Fuel Saving Technologies
12.0%
10.0%
Mass+Secondary
8.0%
Better
6.0%
Cylinder Deact on SOHC
Mass Reduction
Aero Drag Dred.
Turbo
4.0%
VVT-ICP Improved Auto Trans
Engine Friction Reduction
EGR Boost Combustion Restart Cylinder Deact. On OHV
Electric Power Steering
Belt Mounted BMISG VVT - CCP on OHV
2.0%
DVVL on DOHC
Low Drag Brakes 6/7/8 speed Auto Trans
Electric Power Steering
Engine Friction Reduction
0.0%
$- $100.00 $200.00 $300.00 $400.00 $500.00 $600.00 $700.00
Source: EPA/NHTSA Joint Technical Support Document – Final Rulemaking;
Mass + Secondary – Alum. Association/IBIS
AluminumInTransportation.org
15. Conclusions
• Incredible growth for aluminum in cars
• Passenger vehicle bodies will no longer be dominated
by a single material
• The aluminum industry can and will increase
capacity to support an aluminum intensive fleet
in 2017-2025
• High volume aluminum-intensive vehicles will be in
showrooms in the next 5 years
The aluminum revolution in cars continues to roll!
AluminumInTransportation.org
