Advancing Growth

2015 North American 

Light Vehicle Aluminum 

Content Study

Executive Summary 

June 2014
Executive Summary

2015 Key Findings

2

In 2015:

• Pickup trucks will contain the most aluminum at 548.9 lbs. per vehicle, followed closely by E Segment

sedans at 546.9 lbs., SUVs at 410.3 lbs. and minivans at 396.5 lbs. All other segments will be below the

average content of 394 pounds per vehicle.

• Tesla, Mercedes, BMW and Ford will all exceed the average aluminum content and the average 

aluminum share of curb weight.

• The F-150 will contain 1,080 pounds of aluminum. Aluminum sheet and extruded products for the 

body and closures are over one half of this content.

• The total aluminum content for the 17.46 million vehicles of expected production will equal nearly 7 

billion pounds. Body and closure parts will be 11% of the total.

• Total North American light vehicle aluminum consumption will increase by 28% in 2015 over 2012.

• Consumption will surpass all records set in previous decades by one billion pounds.

• Aluminum hood penetration will increase from 34% in 2012 to 48% in 2015.

• More than 500,000 pickup trucks and EV’s (a combined total) will have complete aluminum bodies, 

and have a content of over 500 million pounds of aluminum.
Executive Summary

2025 Key Future Projections

3

Within the Decade:

• Seven out of 10 new pickup trucks produced in North American will be aluminum-bodied.

• Every leading automaker will have an aluminum body program in place.

• Ford, General Motors and Fiat Chrysler will be the biggest users of aluminum sheet.

• Aluminum hood penetration will reach 85% and doors will reach 46%; complete bodies will reach 

18%, from less than one percent today. This will drive total aluminum content to 547 pounds per 

vehicle.

• The total North American aluminum content will be 10 billion pounds.

• Aluminum will comprise more than 75% of pickup truck body and closure parts, 24% of E Segment 

body and closure parts, 22% of SUV body and closure parts and 18% of minivan body and closure 

parts.

• Aluminum sheet for light vehicle body and closure parts will grow from less than 200 million pounds 

in 2012 to nearly 4 billion pounds.

• On a volume basis, 26.6% of all the body and closure parts will be made of aluminum.

• The gross weight savings from aluminum body and closure use will be 175 pounds per vehicle.

• Globally, light vehicle aluminum content will approach 35 billion pounds, making light vehicles the 

most important global market for aluminum.
Executive Summary

 Aluminum content will break with the long term 40 year trend line in 2015 as aluminum penetration for 

body parts, doors and closures (other than hoods)finally reaches the critical mass for an explosive period of 

growth from 2015 to 2025.

Net Aluminum Pounds per Light Vehicle

450

400

350

350

300

250

200

150

100

50

0

Calendar Year

4

394

19751976197719781979198019811982198319841985198619871988198919901991199219931994199519961997199819992000200120022003200420052006200720082009201020112012201320142015

N

et 

Pounds per 

Vehicle
Executive Summary

22.3

12.6

5

5.4

3

2 0 1.4 1.5

1

0

1

5

2

0

 Large content increases for body parts, closures and larger transmission cases will more than offset small

content losses for smaller engines and stiff competition from new steels for suspension control arms over

the period 2012 to 2015.

 The net increase is expected to be a plus 44.3 pounds per vehicle from 2012 to 2015 compared to an 

increase of only 10 pounds per vehicle from 2010 to 2012.

Component or System Changes for Aluminum Content in 2015 versus 2012

25

Net Gainsin Pounds per Vehicle

-2.4

Engines Control Arms Other Losses

& Links -0.3

-1.2

0

-0.5

-1

-1.5

-2

-2.5

-3

Net Losses in Pounds per Vehicle

+48.2 lbs. (3.9) lbs.

5
Executive Summary

 Total North American light vehicle aluminum consumption will increase by 28% in 2015 over 

2012.

– The increase is an equal combination of more vehicles and more aluminum content per vehicle.

 Consumption in 2015 will surpass any records set in previous decades by one billion pounds.

Aluminum Consumption for Light Vehicles

5395

6886

5000

4000

3000

2000

1000

0

6000

8000

7000

2012 2015

Millions of

Pounds

6
Executive Summary

 In 2015, the total aluminum content for the 17.46 million vehicles of expected production will equal 

nearly 7 billion pounds.

– Body and closure parts will be 11% of the total.

– 33% of the content will be for engine parts.

161

803

812

629

1325

658

1083

173

243

143

80

777

0 500 1000 1500

All other

Blocks

Heads

Other Engine

Transmission & Driveline

Heat Transfer

Wheels

Brakes

Steering

Suspension

Bumpers

Body & Closures

Millions of Net Al Pounds by 

Component/System

2%

12%

12%

9%

19%

10%

16%

2%

4%

2%

1%

11%

Component/System Share of Al 

Consumption

All other 

Heads

Transmission & Driveline 

Wheels

Steering 

Bumpers

Blocks

Other Engine 

Heat Transfer 

Brakes 

Suspension 

Body & Closures

6.9 Billion Pounds

7
Executive Summary

 Aluminum’s share of the 3,798-pound curb weight in 2015 is expected to be 10.4%.

– This is compared to the 9% share of the 3,828-pound curb weight in 2012.

 Tesla, Mercedes, BMW and Ford will exceed the average aluminum content and the average aluminum share 

of curb weight for 2015 .

9.0%

8
Executive Summary

D Segment 

Chevy Malibu 

Dodge Charger 

MUSTANG

E Segment 

Cadillac XTS 

STING RAY

VAN Segment 

Dodge Sprinter 

Ford Transit

PUP Segment 

Ford F150

Ram 1500

 As aluminum content spreads across vehicle segments, the E Segment, SUV Segment and PUP Segment 

emerge as content leaders.

2015 Vehicle Segment Average Aluminum Pounds and Share of 2015 Production

9

A/B Segment 

Fiat 500 

Ford Fiesta

C Segment

Ford Focus

Honda Civic

MPV Segment 

Honda Odyssey 

Chrysler Town& 

Country

SUV Segment 

Chevy Suburban

Jeep Grand Cherokee

251.6 lb.’s

273.9 lb.’s

363.3 lb.’s

546.9 lb.’s

396.5 lb.’s

410.3 lb.’s

273.2 lb.’s

548.9 lb.’s

3% of Production

17% of Production

21% of Production

2% of Production

4% of Production

33% of Production

2% of Production

17% of Production
Executive Summary

 The aluminum-bodied F-150 goes into production later this year.

 This is the first high-volume aluminum-bodied vehicle to go into production in the world.

 When the program reaches full production in 2016, Ford will be making 850,000 trucks per year 

and require 350,000 tons of aluminum sheet per annum.

 The 2015 Ford F-150 is a test case for a high-volume aluminum vehicle, achieving ~ 700 lbs. of weight 

savings over the current model.

Redesigned 2015 F-150

600 Pounds (Excludes 70 pounds of 

extruded aluminum products)

10
Executive Summary

7%

6%

3%

6%

1%

2%

1%

3%

1%

7%

1%

0%

21%

26%

9%

3%

3% 1%

2015 F-150 Crew Cab 

Net Aluminum Content Blocks 

Heads

Other Engine 

Transmission Cases 

Other Transmission 

Differential Carriers

Drive shafts & Yokes 

Heat Exchangers

Heat Shields and Sinks 

Wheels

Brakes 

Steering 

Closures

Body Sheet HT 

Body Sheet NHT 

Body Shapes 

Body Tube

All other

1,080 Pounds 

25% of Curb Weight

11

 The 2015 Ford F-150 will have over 1,000 pounds of net aluminum content, or approximately 25% of its 

curb weight.

2015 F150 Crew Cab Lbs. / Vehicle

CY2015

Blocks 71

Heads 66

Other Engine 37

Transmission Cases 68

Other Transmission 12

Differential Carriers 17

Drive shafts & Yokes 7

Heat Exchangers 32

Heat Shields and Sinks 10

Wheels 72

Brakes 6

Steering 5

Closures 223

Body Sheet HT 281

Body Sheet NHT 96

Body Shapes 31

Body Tube 37

All other 9

Total 1080
Executive Summary

NA Aluminum Sheet Demand 

For Auto Body and Closure Parts

4500

4000

3500

3000

2500

2000

1500

1000

500

0

2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023 2024 2025

12

Millions of

Pounds

 Aluminum sheet for light vehicle 

body and closure parts will grow 

from less than 200 million 

pounds in 2012 to nearly 4 

billion pounds by 2025.

 This growth of aluminum rolled 

products for automotive 

applications will require a 

tremendous increase in heat 

treating capacity.

 Ford, General Motors and Fiat 

Chrysler will be the biggest 

users of aluminum sheet

 Every leading automaker will 

have several aluminum body 

and closure panel programs by 

2025.

 26.6% of all the body and 

closure parts on a volume basis 

will be made of aluminum in 

2025.

 70% of the aluminum sheet will 

need to be 6xxx heat treatable 

sheet.
Executive Summary

 The number of vehicles with aluminum closures and complete body structures will increase by significant 

proportions over the next ten years.

34%

48%

6% 6% 7%

4% 4%

73%

19%

28%

33%

26%

30%

24%

9%

85%

27%

46%

18%

0%

10%

20%

30%

40%

70%

60%

50%

80%

90%

Hoods Fenders Doors

2015

Trunk/Gate

2020 2025

Roof Complete Bodies

S

h

are of All Lig

ht Ve

hicles

Aluminum Penetration for Closures 

and Complete Bodies

2012

The chart does not include the numerous vehicles that will also have partial body structures, vacuum die cast shock towers and other VD cast body parts.

13
Executive Summary

 The material mix for body and closure parts will change dramatically over the next ten years.

 On a weight basis, aluminum will grow to 19% of the weight for body and closure parts by 2025.

861, 84%

154, 15%

8, 1% 2012

Mild and HSLA 

AHSS/UHSS

Aluminum Sheet 

Aluminum Extrusions 

Aluminum VD Castings

751, 76%

201, 20%

37, 4%

3, 0%

1, 0% 2015

Mild and HSLA 

AHSS/UHSS

Aluminum Sheet 

Aluminum Extrusions 

Aluminum VD Castings

559, 59%

277, 29%

92, 10%

8, 1%

5, 1% 2020

Mild and HSLA 

AHSS/UHSS

Aluminum Sheet 

Aluminum Extrusions 

Aluminum VD Castings

366, 41%

357, 40%

144, 16%

13, 2%

8, 1% 2025

Mild and HSLA 

AHSS/UHSS

Aluminum Sheet 

Aluminum Extrusions 

Aluminum VD Castings

14

1023 lbs. 993 lbs.

941 lbs. 888 lbs.
Executive Summary

 A mild, HSLA and bake hard steel body structure with closures weighs on average 1,060 pounds.

 This excludes bumpers and the 500-pound ladder frame for pickup trucks.

 By 2025, the weight for the average body with closures will be 888 pounds.

– This is based on a constant vehicle footprint of 49 square feet.

 New materials, including aluminum, will continue to save weight without sacrificing safety, size or 

efficiency.

1200

0

2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023 2024 2025

200

600

400

800

1000

N

et 

Pounds for 

Body and Closures

Aluminum VD Castings 

Aluminum Extrusions 

Aluminum Sheet 

AHSS/UHSS

Mild and HSLA

15
Executive Summary

 By 2025, 26.6% of all the body and closure parts for light vehicles in North America will be made of 

aluminum (measured by volume rather than weight).

 A burst of aluminum activity is expected in the few years leading up to the 2025 EPA mandate of 161 grams 

of CO2 per mile taking full effect.

1.4% 1.7%

3.2%

6.6%

9.3%

10.7% 11.5%

13.7%

16.9%

19.0%

25%

22.1%

20.2%

25.6%

26.6%

0%

2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023 2024 2025

5%

10%

15%

20%

30%

Aluminum Volume Share of 

Body and Closure Components

16
 Pickup trucks will demonstrate the highest penetration of aluminum parts for bodies and closures at more 

than 75% by 2025.

 If the fuel economy achieved with powertrain changes does not achieve projected levels, additional fuel 

economy improvements can be achieved through additional aluminum based weight savings on C, D and SUV 

segment vehicles. Other segments such as minivans and E segment cars are also candidates for additional 

weight savings, but their volumes are too small to have a significant impact on CO2 emissions.

Aluminum Volume Share of Body and Closure Components by Vehicle Type

22.1%

4.0% 4.8%

59.3%

11.5% 10.8%

75.9%

22.0%

17.7%

0%

10%

20%

50%

40%

30%

70%

60%

80%

Pickup Trucks SUV / CUV Minivan

2015 2020 2025

Executive Summary

17
Executive Summary

 In the car segments, E Segment vehicles will show the highest aluminum penetration for body and closure 

parts at nearly 24% by 2025.

 Weight savings estimates remain conservative for C segment and D segment cars given they are the prime 

candidates for hybrid and electric powertrains. Alternative powertrain assumptions will be severely 

challenged by the high cost of hybrid, plug-in and all-electric technologies. A low-cost, low weight battery 

solution is not yet on the horizon.

Aluminum Volume Share of Body and Closure Components by C, D & E Segment Cars

4.7%

2.5%

0.7%

0%

7.8%

5.2%

3.9%

23.9%

13.8%

8.7%

5%

10%

15%

20%

25%

30%

E Segment D Segment C Segment

2015 2020 2025

18
33%

41%

23%

2% 1%

2025

Mild and HSLA 

AHSS/UHSS

Aluminum Sheet 

Aluminum Extrusions 

Aluminum VD Castings

Executive Summary

 Extensive use of aluminum, dual phase, complex phase and press hardened steels will be required to 

remove 150-200 pounds out of the average auto body with closures by 2025. To remove more than 200 

pounds it will require aluminum to be used for over 30% of the parts.

Light Vehicle Body and Closure Part Volume Share by Material

81%

18%

1%

2012

Mild and HSLA 

AHSS/UHSS

Aluminum Sheet 

Aluminum Extrusions 

Aluminum VD Castings 71%

23%

6%

2015

Mild and HSLA 

AHSS/UHSS

Aluminum Sheet 

Aluminum Extrusions 

Aluminum VD Castings

52%

31%

15%

1% 1% 2020

Mild and HSLA 

AHSS/UHSS

Aluminum Sheet 

Aluminum Extrusions 

Aluminum VD Castings

19
Executive Summary

 As aluminum grows to 26% of the part volume for light vehicle bodies and closures, the total amount of 

material needed in 2025 will decline by over 3 billion pounds per year over the need in 2012.

Cumulative Savings

of 175 pounds per vehicle 

from 239 pounds

of Aluminum Additions 

per vehicle

0

2012 2013 2014 2015 2016 2017 2018

Savings due to Aluminum Sheet 

Savings due to Aluminum VD Castings

1,000

500

1,500

2,000

2,500

3,000

3,500

2019 2020 2021 2022 2023 2024

Savings due to Aluminum Extrusions

2025

Millions of

Pounds

S

a

ved

Gross Weight Savings for Body & Closure Parts

2012-2025

20
Executive Summary

 Fifty years of uninterrupted aluminum growth for North American manufactured light vehicles is 

guaranteed. There is nothing on the horizon that would indicate that this burst in aluminum growth can be 

significantly slowed over the next ten years.

120

139

165

212

258

340

306

394

473

547

0

1975 1977 1979 1981 1983 1985 1987 1989 1991 1993 1995 1997 1999 2001 2003 2005 2007 2009 2011 2013 2015 2017 2019 2021 2023 2025

Calendar Year

100

200

300

400

500

600

N

et 

Pounds per 

Vehicle

Aluminum Net Pounds per North American Light Vehicle

21
Executive Summary

 Aluminum heat treated and non-heat treated sheet, extruded shapes and tube as well as vacuum assisted 

high pressure die castings are the products that will benefit the most from the need to use more aluminum 

to save weight and improve fuel economy by 90% by 2025.

 All other product forms including conventional HPDC, permanent mold castings, brazing sheet, fin stock, 

rod and bar and forgings will only increase by 27 pounds in total over the period 2012 to 2025.

Net Pounds per Vehicle for Select Product Forms

13.4

19.1

42

24.6

1

0

97

35

7

150

42

20 12

40

60

80

140

120

100

160

Rolled Products Extruded Produts Vacuum Die Castings

N

et P

ounds per Vehicle

2012

2015

2020

2025

This chart excludesrod and bar, fin stock, brazing sheet, forgings and all castings except VDC

22
Executive Summary

20

18

16

14

12

10

8

6

4

2

0

1999 2012 2015

Secondary

2020 2025

Millions of

Tons

Global Light Vehicle Aluminum Use 

History and Forecast

(includes scrap)

Primary

43%

55% 54 Million 

Vehicles

57%

45%

8.7

Will be 

closer to 50/50, 

if sheet prompt 

scrap is closed 

loop recycled

4.9

11.4

14.8

30 - 35 million tons if the world 

follows NA

120 Million 

Vehicles

18 Million Ton Base 

20 Million Ton Upside

23

 Light vehicles will be the most important global market for aluminum in the coming decade.
This concludes our report. Thank you.

This presentation was prepared by Ducker Worldwide LLC. Opinions and estimates constitute

judgment as of the date of this material and are subject to change without notice. Any

interpretations derived from these findings are the sole responsibility of the client.

Reproductionwithout the explicitconsent of DuckerWorldwide LLC is strictly prohibited.

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24