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

4

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

5

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

Group’s Mission

6

• 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 CO2 emissions by 30 tons 

and increase payload capacity by 3,300 lbs. in 

weight-constrained heavy trucks 7
Aluminum Builds a Better 

Vehicle

8

Reduced 

Emissions

Mass 

Reduction

Enhanced 

Performance Improved 

Safety

Better Fuel 

Economy

Infinitely 

Recyclable
Lightweighting Lessons from 

the Auto Sector

9

• 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

13

• 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?

14

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

Source: Alcoa 2008, Q4 research 15
Aluminum Already on the Road 

Increases Payload and Fuel Economy

16

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

17

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

18

• 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

19

• Results based on realworld 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

Car City Bus

(diesel)

Articulated

Truck

Road Vehicles
Estimated Fuel Economy Benefit from 

10% Weight Reduction

20

Source: IFEU, SGKV 2002
Aluminum Wheels Pay Fuel 

Economy Dividends

Source: Smithers Scientific Services 21

3% reduction in rolling resistance = 1% fuel savings

3%
Aluminum Helps Reduce CO2

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 CO2 Equivalent (CO2e)

Steel vs. Aluminum

CO2 Generated in 

Use of the Truck **

CO2 Generated in 

Material Production

** Assumes 10% weight save

5% less lifecycle CO2
Aluminum Helps Reduce CO2

23

Specific Savings

(Tons of CO2 per ton of w eight save)

28

18 23

3

53

0

10

20

30

40

50

60

Bus - Urban

Bus -

Suburban

Truck -

Weight

Constrained

Truck -

Volume

Constrained

Car

Source: IFEU, 2003

Specific CO2 Savings Per Ton of Weight Save

30 tons CO2lifecycle 

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.worldaluminium.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

Source: IAI and Alcoa 24
China Bus Project: Real World 

Success

25

• Value – Ecological

• Reduction in CO2

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 

CO2 Lifetime

Spaceframe

Extrusions

Wheel

Body Panel

Source: Alcoa
Aluminum is a Part of the 

Solution

26

• 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 CO2 emissions 

– Save 18 tons of CO2for every ton 

of aluminum you add to your fleet 
Get Involved

27

• 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