The presentation discusses how aluminum can benefit commercial vehicles by reducing weight. It provides an overview of challenges facing the industry such as rising fuel costs and emissions regulations. Aluminum offers benefits like increased payload and reduced fuel consumption and emissions. Research shows aluminum weight savings of 3,000-3,500 lbs for trucks can improve fuel economy by 5-10%. Emerging aluminum technologies could save over 3,500 lbs. Aluminum wheels and other components already save over 1,000 lbs on trucks on average. The presentation promotes aluminum as part of the solution to industry challenges through weight reduction and improved sustainability.
3. Our Mission
• Central resource for the
automotive industry on
aluminum
• Promote research and
programs highlighting
advantages
• Expanding mission to
include commercial
vehicles
3 www.autoaluminum.org
Session CV702
5. Research Validates Benefits of
Lightweighing
ASSOCIATION SPONSORED RESEARCH
15
• Safety: Size vs. Weight (DRI 2004)
13
• Vehicle Structure: Manufacturing Weight reduction & resizing
% Fuel Economy Improvement
11
and Lifecycle Cost Analysis (IBIS 10% 6-7%
2005) 9
• Improving Sustainability in the 7
Transport Sector Through Weight 5
Reduction and the Application of 3
Aluminum (IAI 2006)
1
• Benefit Analysis: Use of Aluminum 0 5 10 15 20 25
Structures in Conjunction with % Weight Reduction
Small Car - Resized Engine Mid Size Car - Resized Engine Small SUV - Resized Engine
Alternative Powertrain Large SUV - Resized Engine Truck - Resized Engine Small Car - Baseline Engine
Technologies in Automobiles (IBIS Mid Size Car - Baseline Engine Small SUV - Baseline Engine Large SUV - Baseline Engine
Truck - Baseline Engine
2008)
• Aluminum Growth Study (Ducker Impact of Vehicle Weight Reduction on Fuel Economy for
2009 & 2006) Various Vehicle Architectures (Ricardo 2007)
5
Session CV702
6. Validation Leads to
Continuous Growth
North American Light Vehicle Aluminum
Content Continues to Climb
Source: Ducker 2009
6
Session CV702
7. Why We Are Here Today
• Apply our auto industry model to the commercial vehicle
industry
• Lightweighting with aluminum can help you tackle the
challenges
• Auto companies and other third-parties acknowledge aluminum’s
value proposition will help them meet 2016 CAFE standards
• Overview
• Industry challenges
• Value proposition
• Weight saving benefits
• Research and data
7
Session CV702
8. Challenges Facing Industry
• Rising energy costs
• Growing concern over
greenhouse gas emissions
• Federal mandates
continue to add weight to
heavy-duty vehicles
• Weak economy
Of the 83 million barrels of crude oil used per day,
trucks account for more than half of the oil used in
transportation and its share is projected to increase
Source: International Energy Outlook 2005; U.S. EIA
8
Session CV702
9. Why Aluminum for Commercial
Vehicles?
THE VALUE PROPOSITION
• Increased payload
• Lower maintenance costs
• Reduced fuel
consumption
• Reduced greenhouse gas
emissions
• Improved durability
According to the U.S. EPA, a 10% drop in
• Higher resale value
truck weight reduces fuel use between 5-10%
• Infinitely recyclable
9
Session CV702
10. Truck Owners See Value in
Lightweighting
Source: Alcoa 2008, Q4 research
10
Session CV702
11. Aluminum Already on the Road
• Cab structure
• Trailer side walls and structure
The average Class 8 Tractor today
• Flatbeds/tippers/dump bodies
contains 1,000 lbs. of aluminum
• Forged aluminum wheels
• Frame cross members
• Coal trucks
• Fifth wheel
• Fuel tanks
• HVAC components
• Landing gear
• Tank bodies
• Bellhousing
11
Session CV702
12. How Much Weight is Being Saved?
Tractor
• Axle hubs = 120 lbs.
• Centrifuse brake drums = 100 lbs.
• Clutch housing = 50 lbs.
• Front axle leaf springs = 70 lbs.
Trailer
• Roof posts = 75 lbs.
• Floor joists = 300 lbs.
• Upright posts = 600 lbs.
Aluminum wheels on a tractor can
save 30 lbs. each for a total savings • Hubs and wheels = 900 lbs.
of 300 lbs.
Source: U.S. EPA Weight Reduction Fact Sheet 2004
12
Session CV702
13. Emerging Technologies Save More
Weight
3,500 lbs. weight savings potential
Cab Rear Wall Rear Door
Cab Roof Save 49 lbs. RR Door Surround Save 187 lbs.
Save 60 lbs. Save 150 lbs.
Save 20 lbs.
per door Side Wall
Save 1,000 lbs.
Cab Floor
Save 56 lbs.
Landing Gear
Save 50 lbs.
Slider Box
Save 150 lbs.
Frame Rails Cab X-Member Save 30 lbs. per
Save 435 lbs. Save 38 lbs. wheel
13
Session CV702
14. Research Supporting Our
Value Proposition
• Potential Savings as a Result of Weight
Reduction (IFEU Heidelberg 2003)
• Improving Sustainability in the Transport
Sector via Weight Reduction and
Application of Aluminum (IAI 2006)
• Case Study: China Bus Project (Alcoa
2008)
• Impact of Weight on Rolling Resistance
and Fuel Economy (Smithers 2009)
• Simulator Data (Major Tire Manufacturer
2007
14
Session CV702
15. IFEU Heidelberg Research Findings
• Results based on real-
world experience of truck
OEMs
• Weight is a factor in truck
and bus fuel economy
• Trucks and buses
represent a large potential
fuel savings
• Duty cycle dependant
Source: IFEU, SGKV 2002
15
Session CV702
17. Impact More Pronounced in
Urban Setting: Bus Example
Physical resistances have an impact
on vehicle fuel efficiency and mass of Duty cycle is important factor
the vehicle is a significant factor
3. Gradient Resistance
FSt = m. g. sin a
G = m. g.
Impact is more pronounced in urban setting
17 Source: IFEU, Alcoa
Session CV702
18. China Bus Project: Real World Success
Weight >6% Fuel
50 Tons of
Reduction of Economy
CO2 Lifetime
1,400 kg (12%) Improvement
Value – Ecological
Space Frame
• Reduction in CO2 emissions
Extrusions
• Reduced road surface wear
and tear
Value – Financial
• Less fuel
• Maintenance savings (tires,
brakes, suspension)
• Improved corrosion resistance Wheel
• Payback of 2-3 years Body Panel
18 Source: Alcoa
Session CV702
19. Relevant Auto Study: Aluminum Adds
Value to Alternative Powertrains
19 Source: IBIS Associates
Session CV702
20. Aluminum Wheels Pay Fuel Economy
Dividends
An aluminum
wheel can improve
tire rolling
resistance by up to
3% over a
comparable size
steel wheel
3% less rolling resistance
=1% fuel savings
Source: Smithers Scientific Services
20
Session CV702
21. Major Tire Manufacturer
Simulator Data
Base Weight 16,340 36,312 36,312
Drive Cycle HTUF Regional HTUF
Source: Major Tire Manufacturer
21
Session CV702
22. IAI Transport Model Illustrates Potential
CO2 Savings from Lightweighting
User Input Output
Specifications
Final energy savings
of vehicles and
through lightweighting
components
Customer CO2 equivalent savings
scrap thought lighweighting
generation IAI/EAA/AA Carbon footprints of
Fuel/electricity
consumption
Transport aluminum and
competing material
during use Lifecycle
Vehicle recycling
Model
Industry Inputs
CO2 equivalents
Final energy
Aluminum
production date
Source: IAI
22
Session CV702
23. IAI: Aluminum Helps Reduce CO2
Specific Savings
• Auto aluminum already (Tons of CO2 per ton of w eight save)
saving 300 million
metric tons of CO2 60
53
annually 50
40
• Including CO2 impact of 28
aluminum production 30
18
23
20
• Use-phase savings far
10
outweigh production 3
0
CO2 generation
Constrained
Constrained
Bus - Urban
Car
Suburban
Bus -
Truck -
Truck -
Volume
Weight
• Recycled aluminum
uses 95% less energy Potential
Weight
Savings: 3,000-3,500 lbs. 3,500-4,500 lbs. 300-500 lbs.
Source: IFEU, 2003
23
Session CV702
24. Use-phase Savings Outweigh
Production Energy Generation
GJoules
Source: Alcoa – Automotive Example
24
Session CV702
25. Aluminum is a Part of the Solution
More Payload AND Lower Costs
• One ton of weight reduction = up to
588 gallons of diesel per year
• Lower maintenance costs
• Lower tire and brake costs
Higher residual value and durability
• Corrosion resistant parts last longer
Reduced Lifetime CO2 Emissions
• Save 18 tons of CO2 for every ton of
aluminum you add to your fleet
Reduced dependence on imported oil
Infinitely recyclable
25
Session CV702
26. Help US so that we can help YOU
Research topics
Data gaps to fill
26
Session CV702
27. The Aluminum Advantage
Commercial Vehicle Applications
Todd Summe
Technical Committee, The Aluminum Association’s
Aluminum Transportation Group
Division Manager, Product Design & Development – Alcoa
www.autoaluminum.org
