2009 dec.cv webinar

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2009 dec.cv webinar

  1. 1. The Aluminum Advantage Commercial Vehicle ApplicationsAn Aluminum Association Webinar www.autoaluminum.org
  2. 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 2
  3. 3. Today’s Agenda• Introductions• Background in lightweighting• Aluminum in commercial vehicles • Challenges • Weight-savings potential• Existing research and case studies• Q&A 3
  4. 4. Introductions Randall Scheps Doug Richman Todd Summe ATG Chairman Vice President of Division ManagerMarketing Director of Engineering & Product Design &Ground Transportation Technology Development Alcoa Kaiser Aluminum Alcoa 4
  5. 5. Defining Who We AreThe Aluminum Association’s Aluminum Transportation Group (ATG) 5
  6. 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 6
  7. 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. 8. Aluminum Builds a Better Vehicle Mass Better Fuel Reduction Economy Infinitely Reduced Recyclable Emissions EnhancedPerformance Improved Safety 8
  9. 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 9
  10. 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. 11. Proven Benefits Lead to Continuous Growth North American Light Vehicle Aluminum Content Continues to ClimbSource: Ducker 2009 11
  12. 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 12
  13. 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 increaseSource: International Energy Outlook 2005; U.S. EIA 13
  14. 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 14
  15. 15. Truck Owners See Value in LightweightingSource: Alcoa 2008, Q4 research 15
  16. 16. Aluminum Already on the RoadIncreases Payload and Fuel EconomyLightweighting 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 16
  17. 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. eachCab FloorSave 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. 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) 18
  19. 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 27 • 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 VehiclesSource: IFEU, SGKV 2002 19
  20. 20. Estimated Fuel Economy Benefit from 10% Weight ReductionSource: IFEU, SGKV 2002 20
  21. 21. Aluminum Wheels Pay Fuel Economy Dividends 3% 3% reduction in rolling resistance = 1% fuel savingsSource: Smithers Scientific Services 21
  22. 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 saveSource: Alcoa 22
  23. 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 WeightSource: IFEU, 2003 23
  24. 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.aspSource: IAI and Alcoa 24
  25. 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 25Source: Alcoa
  26. 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 26
  27. 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.orgSource: MEMA and EPA.gov 27
  28. 28. Contact UsFor more information or todownload this presentation Visit www.autoaluminum.org or E-mail ktyll@aluminum.org 28
  29. 29. Question & AnswerPlease submit any questions through the question box on your screen 29
  30. 30. The Aluminum Advantage Commercial Vehicle ApplicationsAn Aluminum Association Webinar www.autoaluminum.org

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