1. The Aluminum Advantage
Commercial Vehicle Applications
An Aluminum Association Webinar
www.autoaluminum.org
2. Why We Are Here Today
• Share lessons learned for sustainable
transportation solutions to economic and
ecologic challenges
• Request feedback to direct research for
commercial vehicle industry
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3. Today’s Agenda
• Introductions
• Background in lightweighting
• Aluminum in commercial vehicles
• Challenges
• Weight-savings potential
• Existing research and case studies
• Q&A
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4. Introductions
Randall Scheps Doug Richman Todd Summe
ATG Chairman Vice President of Division Manager
Marketing Director of Engineering & Product Design &
Ground Transportation Technology Development
Alcoa Kaiser Aluminum Alcoa
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5. Defining Who We Are
The Aluminum Association’s Aluminum Transportation Group (ATG)
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6. The Aluminum Transportation
Group’s Mission
• Central resource for the
trucking and automotive
industries on aluminum
• Promote research and
programs highlighting
advantages of
lightweighting with
aluminum
www.autoaluminum.org
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7. 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
8. Aluminum Builds a Better
Vehicle
Mass Better Fuel
Reduction Economy
Infinitely Reduced
Recyclable Emissions
Enhanced
Performance Improved
Safety
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9. Lightweighting Lessons from
the Auto Sector
• 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
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10. 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
11. Proven Benefits Lead to
Continuous Growth
North American Light Vehicle Aluminum
Content Continues to Climb
Source: Ducker 2009
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12. 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; ½ GCW; un-loaded
– Driving conditions
• EPA HWFET, WVU Interstate and HUDDS cycles
– Timing
• Publication expected Q1-2010
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13. Challenges Facing the
Commercial Vehicle 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
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14. Why Aluminum for Commercial
Vehicles?
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
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15. Truck Owners See Value in
Lightweighting
Source: Alcoa 2008, Q4 research 15
16. Aluminum Already on the Road
Increases Payload and Fuel Economy
Lightweighting Options Weight-Savings Potential
• Cab structure
• Forged aluminum wheels
• Hubs
1,500 lbs.*
• Frame cross members
• Fuel tanks
• Trailer side walls and structure
• Flatbeds 3,500 lbs.
• Tank bodies 7,000 lbs.
* Relative to base truck & box trailer
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17. Emerging Technologies Save
More Weight
3,300 lbs. total weight savings potential
(truck & box van)
Cab Roof Cab Rear Wall Rear Door
Doors Save 60 lbs. RR Door Surround Save 187 lbs.
Save 20 lbs. Save 49 lbs. Save 150 lbs.
each
Cab Floor
Save 56 lbs.
Landing Gear
Save 50 lbs.
Fifth Wheel
Save 100 lbs. Slider Box
Bogey X-Member Save 150 lbs.
Save 38 lbs.
Frame Rails
Save 435 lbs. 17
18. Research Supporting
Lightweighting with Aluminum
• 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)
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19. IFEU Heidelberg Research
Findings
Lifetime Primary Energy Savings
(GJ/100kg)
• Results based on real-
70
world experience of truck 62
60
OEMs
• Weight is a factor in truck 50
and bus fuel economy 40
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• Trucks and buses 30 25
20
25
represent a large potential 20
fuel savings 10
• Duty-cycle dependant 0
Car Car City Bus Long Articulated
(gasoline) (diesel) Distance Truck
Bus
Road Vehicles
Source: IFEU, SGKV 2002 19
22. Aluminum Helps Reduce CO2
Lifecycle CO2 Equivalent (CO2e)
Steel vs. Aluminum
1400
5% less lifecycle CO2
1200
1000
Mega Tons of CO2e
800
CO2 Generated in
Use of the Truck **
600 1170 1106 CO2 Generated in
Material Production
400
200
0 8 16
Steel Intense Aluminum
Truck Intense Truck ** Assumes 10% weight save
Source: Alcoa 22
23. Aluminum Helps Reduce CO2
Specif ic Savings
Specific COof Savingston ofTon of Weight
(Tons 2 CO2 per Per w eight save) Save
60
53
50
30 tons CO2 lifecycle
savings
40
Tons of CO2
28
30
23
18
20
10
3
0
Constrained
Constrained
Bus - Urban
Car
Suburban
Truck -
Truck -
Bus -
Volume
Weight
Source: IFEU, 2003 23
24. 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
Source: IAI and Alcoa 24
25. China Bus Project: Real World
Success
Weight >6% Fuel
50 Tons of
Reduction of Economy
CO2 Lifetime
1,400 kg (12%) Improvement
• Value – Ecological
Spaceframe
• Reduction in CO2 Extrusions
emissions
• Reduced road surface
wear and tear
• Value – Financial
• Less fuel
• Maintenance savings
(tires, brakes, suspension) Wheel
• Improved corrosion Body Panel
resistance
• Payback of 2-3 years 25
Source: Alcoa
26. 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
– 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 CO2 for every ton
of aluminum you add to your fleet
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27. Get Involved
• 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
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28. Contact Us
For more information or to
download this presentation
Visit www.autoaluminum.org
or
E-mail ktyll@aluminum.org
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