# The Aluminum Advantage

Commercial Vehicle Applications 

# An Aluminum Association Webinar

www.autoaluminum.org

# Why We Are Here Today

2 

# • Share lessons learned for sustainable 

# transportation solutions to economic and ecologic challenges • Request feedback to direct research for commercial vehicle industry

# Today’s Agenda • Introductions 

# • Background in lightweighting • Aluminum in commercial vehicles • Challenges • Weight-savings potential 

# • Existing research and case studies 

# • Q & A 3

# Introductions

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### Randall Scheps ATG Chairman Marketing Director of Ground Transportation Alcoa Todd Summe Division Manager Product Design & Development Alcoa Doug Richman Vice President of Engineering & Technology Kaiser Aluminum

# Defining Who We Are

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### The Aluminum Association’s Aluminum Transportation Group (ATG)

# The Aluminum Transportation



# Group’s Mission

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### • Central resource for the trucking and automotive industries on aluminum 

### • Promote research and programs highlighting advantages of lightweighting with 

### aluminum www.autoaluminum.org

# Did You Know?
• Aluminum is the most abundant metal in the earth’s crust • 73% of all aluminum produced since 1888 is still in use today • Recycled aluminum uses 95% less energy to produce than primary output • The aluminum industry has cut greenhouse gas factory emissions per ton of aluminum produced by 30% since 1990, and aims to be carbon neutral by 2030 • Weight saving with aluminum has the potential to reduce lifecycle CO 2 emissions by 30 tons and increase payload capacity by 3,300 lbs. in weight- constrained heavy trucks 7

# Aluminum Builds a Better



# Vehicle

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Reduced Emissions Mass Reduction

Enhanced Performance Improved Safety Better Fuel Economy Infinitely Recyclable

# Lightweighting Lessons from



# the Auto Sector

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### • Crash safety study

– Size not weight is a better determinant of automotive safety 

### • Powertrain study

– Consumers “paid back” faster at the pump when automakers reduce vehicle weight

# Research Validates Benefits of



# Lightweighting
• Vehicle weight reduction study

– Fuel economy improvement of 5 -7% is expected with 10% weight reduction 

### • Cost study

– Impact of aluminum structure mass savings on weight and cost reduction of powertrain and chassis systems reduces the cost premium 

### • Electric vehicle study

– Opting for high -strength, low-weight aluminum structures for plug - in electric and hybrid vehicles can cut vehicle price overall by reducing the battery energy requirements and the associated costs 

### • Growth study

– After nearly four decades – the percentage of aluminum content continues to climb in light vehicles 10

# Proven Benefits Lead to 

# Continuous Growth

11 Source: Ducker 2009 North American Light Vehicle Aluminum Content Continues to Climb

# Upcoming Commercial Vehicle



# Research • Class 8 Commercial Tractor-Van Fuel Consumption Study with Ricardo

– Objective • Quantify fuel consumption impact of weight reduction



### – Methodology • Analytical simulation



### – Vehicle content • Conventional construction; traditional lightweighting; potential future lightweight applications



### – Evaluation loading • GVW; 1⁄2 GCW; un - loaded



### – Driving conditions • EPA HWFET, WVU Interstate and HUDDS cycles



### – Timing • Publication expected Q1 -2010 12

# Challenges Facing the 

# Commercial Vehicle Industry

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## • 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

# Why Aluminum for Commercial



# Vehicles?

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## THE VALUE PROPOSITION • Increased cargo capacity – up 

### to 3,300 lbs. • Reduced fuel consumption and emissions • Lower maintenance costs 

### • Improved durability • Higher resale 10% weight reduction = up to a 5.5% improvement in fuel economy for

Class 8 Trucks

# Truck Owners See Value in



# Lightweighting

15 Source: Alcoa 2008, Q4 research

# Aluminum Already on the Road 

# Increases Payload and Fuel Economy

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### Lightweighting Options • Cab structure • Forged aluminum wheels • Hubs • Frame cross members • Fuel tanks 

### • Trailer side walls and structure • Flatbeds 

### • Tank bodies * Relative to base truck & box trailer 

### Weight-Savings Potential 1,500 lbs.* 3,500 lbs. 7,000 lbs.

# Emerging Technologies Save



# More Weight

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### 3,300 lbs . total weight savings potential (truck & box van) Cab Rear Wall Save 49 lbs. Doors Save 20 lbs. each

Frame Rails Save 435 lbs. Bogey X- Member Save 38 lbs.

RR Door Surround Save 150 lbs.
Landing Gear Save 50 lbs. Cab Floor Save 56 lbs. Slider Box Save 150 lbs . Cab Roof Save 60 lbs. Rear Door Save 187 lbs .

Fifth Wheel Save 100 lbs.

# Research Supporting 

# Lightweighting with Aluminum

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### • Potential Savings as a Result of Weight Reduction (IFEU Heidelberg 2003) • Impact of Weight on Rolling Resistance and Fuel Economy (Smithers 2009) • Improving Sustainability in the Transport Sector via Weight Reduction and Application of Aluminum (IAI 2006) • Case Study: China Bus Project (Alcoa 2008)

# IFEU Heidelberg Research



# Findings

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### • 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 27 25 62
20 25 0 10 20 30 40 50 60 70 

### Lifetime Primary Energy Savings

(GJ/100kg)

Car (gasoline) Long Distance Bus City Bus Car (diesel) Articulated Truck 

### Road Vehicles

# Estimated Fuel Economy Benefit from



# 10% Weight Reduction

20 Source: IFEU, SGKV 2002

# Aluminum Wheels Pay Fuel



# Economy Dividends

21 Source: Smithers Scientific Services



### 3% reduction in rolling resistance = 1% fuel savings

3%

# Aluminum Helps Reduce CO 2

22 Source: Alcoa 8 16 1170 1106
0 200 400 600 800 1000 1200 1400

Steel Intense

Truck Aluminum

Intense Truck Mega Tons of CO2e 

### Lifecycle CO 2 

### Equivalent (CO 2

### e) Steel vs. Aluminum

CO2 Generated in Use of the Truck ** CO2 Generated in Material Production
** Assumes 10% weight save 5% less lifecycle CO 2

# Aluminum Helps Reduce CO 2

23 Source: IFEU, 2003 

### Specific CO 2 

### Savings Per Ton of Weight Save 30 tons CO2 lifecycle savings Tons of CO 2

# Available Modeling Tools

• Improving Sustainability in the Transport Sector Through Weight Reduction and the Application of Aluminium - Model

– Calculate energy savings from lightweighting with aluminum

– Developed inline with ISO 14000 environmental management standards

– http://www.world aluminium.org/Downloads/Publications/M ost%20recent 

### • CalcuLighterTM

– Calculate potential ROI by switching to aluminum wheels

– http://www.alcoa.com/alcoawheels/north_ america/en/calculighter.asp 24 Source: IAI and Alcoa

# China Bus Project: Real World



# Success

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### • Value – Ecological • Reduction in CO 2 emissions • Reduced road surface wear and tear 

### • Value – Financial • Less fuel • Maintenance savings (tires, brakes, suspension) • Improved corrosion resistance • Payback of 2 -3 years 

## Weight 

## Reduction of 1,400 kg (12%) >6% Fuel 

## Economy Improvement 

## 50 Tons of CO 2 

## Lifetime Spaceframe Extrusions

Wheel Body Panel Source: Alcoa

# Aluminum is a Part of the



# Solution

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### • More payload AND lower costs

– One ton of weight reduction = up to 588 gallons of diesel per year

– Carry more cargo

– Lower maintenance costs 

### • Improved fuel economy

– 10% weight reduction = up to a 5.5% improvement in fuel economy for Class 8 Truck 

### • Reduced lifetime CO 2 

### emissions

– Save 18 tons of CO 2 for every ton of aluminum you add to your fleet

# Get Involved

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### • Heavy Duty Manufacturers Association (HDMA) Strategic Energy Council formed within the Motor & Equipment Manufacturers Association (MEMA) 

### • Goals • Improve SmartWaySM Transport program • Influence Congress on energy- related legislation affecting the commercial vehicle supplier industry 

### • Join HDMA today • Contact: Catherine Boland, Director of Government Relations Phone: 202 -312 - 9241 E - mail: cboland@mema.org Source: MEMA and EPA.gov

# Contact Us For more information or to 

# download this presentation Visit www.autoaluminum.org

or 

# E - mail ktyll@aluminum.org 28

# Question & Answer

29 

# Please submit any questions through the 

# question box on your screen

# The Aluminum Advantage

Commercial Vehicle Applications 

# An Aluminum Association Webinar

www.autoaluminum.org