The Aluminum AdvantageExploring Commercial Vehicle Applications              Randall Scheps    Chairman, The Aluminum Asso...
Defining Who We Are                      2
Our Mission• Central resource for  the automotive  industry on aluminum• Promote research and  programs highlighting  adva...
Aluminum Builds a Better Vehicle      Mass                             Better Fuel Economy  Reduction              Infinit...
Association Sponsored Automotive                    Research•   Safety: Size vs. Weight (DRI                              ...
Why We Are Here Today• Lightweighting with aluminum can help you achieve your  goals   – Auto companies and other third-pa...
Why Aluminum for Commercial Vehicles?THE VALUE PROPOSITION• Increased payload• Lower maintenance costs• Reduced fuel  cons...
Truck Owners See Value in LightweightingSource: Alcoa 2008, Q4 research              8
Aluminum Already on the Road•   Cab structure                      The average Class 8 Tractor today contains             ...
Potential Future Applications• Emerging technologies help save more weight       – Save 3,500 lbs. versus today’s truck an...
Research Supporting Our Value Proposition• Potential Savings as a Result of Weight  Reduction (IFEU Heidelberg 2003)• Impr...
IFEU Heidelberg Research Findings     • Weight is a factor in truck       and bus fuel economy     • Trucks and buses repr...
Estimated Fuel Economy Benefit from                                                  10% Weight Reduction                 ...
Impact More Pronounced in Urban Setting                        Bus Example                  Physical resistances have an i...
Rolling Resistance Lab Test• Research conducted by  third-party firm (Smithers)• Tested to SAE spec and  followed U.S. EPA...
Light Weight Pays Fuel Economy                             Dividends                                         An aluminum w...
Light Weight Pays Fuel Economy                                                    Dividends                               ...
Major Tire Manufacturer Simulator Data                                                   Fuel Economy Improvement Per 10% ...
China Bus Project: Real World Success              Weight                        6% Fuel                                  ...
IAI Transport Model Illustrates Potential            CO2 Savings from Lightweighting                      User Input      ...
IAI: Aluminum Helps Reduce CO2   •   Auto aluminum already                                               Specific Savings ...
Aluminum is a Part of the SolutionMore Payload AND Lower Costs•  One ton of weight reduction = up to   2,000 gallons of di...
Questions?             23
The Aluminum AdvantageExploring Commercial Vehicle Applications              Randall Scheps    Chairman, The Aluminum Asso...
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2009 june nas_c_vpres

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2009 june nas_c_vpres

  1. 1. The Aluminum AdvantageExploring Commercial Vehicle Applications Randall Scheps Chairman, The Aluminum Association’s Auto & Light Truck GroupMarketing Director, Alcoa Ground Transportation www.autoaluminum.org
  2. 2. Defining Who We Are 2
  3. 3. Our Mission• Central resource for the automotive industry on aluminum• Promote research and programs highlighting advantages• Expanding mission to include commercial vehicles www.autoaluminum.org 3
  4. 4. Aluminum Builds a Better Vehicle Mass Better Fuel Economy Reduction Infinitely Reduced Recyclable Emissions EnhancedPerformance Improved Safety 4
  5. 5. Association Sponsored Automotive Research• Safety: Size vs. Weight (DRI Impact of Vehicle Weight Reduction on Fuel Economy for 2004) Various Vehicle Architectures (Ricardo 2007)• Vehicle Structure - Manufacturing and Lifecycle 15 Cost Analysis (IBIS 2005) 13• Improving Sustainability in the % Fuel Economy Improvement 11 Weight reduction & resizing Transport Sector Through 10% 6-7% 9 Weight Reduction and the Application of Aluminum (IAI 7 2006) 5• Benefit Analysis: Use of 3 Aluminum Structures in 1 Conjunction with Alternative 0 5 10 15 20 25 Powertrain Technologies in % Weight Reduction Automobiles (IBIS 2008) Small Car - Resized Engine Large SUV - Resized Engine Mid Size Car - Resized Engine Truck - Resized Engine Small SUV - Resized Engine Small Car - Baseline Engine• Aluminum Growth Study Mid Size Car - Baseline Engine Small SUV - Baseline Engine Large SUV - Baseline Engine Truck - Baseline Engine (Ducker 2009 & 2006) 5
  6. 6. Why We Are Here Today• Lightweighting with aluminum can help you achieve your goals – Auto companies and other third-parties acknowledge aluminum’s value proposition will help them meet 2016 CAFE standards – Success experienced in auto industry and same model can apply to the commercial vehicle industry• Overview – Value proposition – Weight saving benefits – Research and data 6
  7. 7. Why Aluminum for Commercial Vehicles?THE VALUE PROPOSITION• Increased payload• Lower maintenance costs• Reduced fuel consumption• Reduced greenhouse gas emissions• Improved durability• Higher resale value• Infinitely recyclable 7
  8. 8. Truck Owners See Value in LightweightingSource: Alcoa 2008, Q4 research 8
  9. 9. Aluminum Already on the Road• Cab structure The average Class 8 Tractor today contains 1,000 lbs. of aluminum• Forged aluminum wheels• Fuel tanks• HVAC components• Bellhousing• 5th wheel• Landing gear• Trailer side walls and structure• Tank bodies 9
  10. 10. Potential Future Applications• Emerging technologies help save more weight – Save 3,500 lbs. versus today’s truck and trailer with aggressive weight reduction Cab Rear Wall Rear Door Cab Roof Save 49 lbs. RR Door Surround Save 187 lbs. Save 60 lbs. Save 150 lbs. Save 20 lbs. per door Side Wall Save 1,000 lbs.Cab FloorSave 56 lbs. Landing Gear Save 50 lbs. Slider Box Frame Rails Cab X-Member Save 150 lbs. Save 435 lbs. Stair/DPF Module Save 38 lbs. Save 30 lbs. per Save 37 lbs. wheel 10
  11. 11. Research Supporting Our Value Proposition• Potential Savings as a Result of Weight Reduction (IFEU Heidelberg 2003)• Improving Sustainability in the Transport Sector Through Weight Reduction and the Application of Aluminum (IAI 2006)• Simulator Data (Major Tire Manufacturer 2007)• Case Study: China Bus Project (Alcoa 2008)• Impact of Weight on Rolling Resistance and Fuel Economy (Smithers 2009) 11
  12. 12. IFEU Heidelberg Research Findings • Weight is a factor in truck and bus fuel economy • Trucks and buses represent a large potential fuel savings • CO2 reductions also • Duty cycle dependant • Results based on real- world experience of truck OEMsSource: IFEU, SGKV 2002 12
  13. 13. Estimated Fuel Economy Benefit from 10% Weight Reduction 9.0% 8.0% 8.0% 7.0% Percent Increase in Fuel Economy 6.0% 5.5% 5.0% 4.0% 3.0% 2.4% 2.0% 1.6% 1.0% 0.0% Truck Truck Bus Bus Volume Constrained Weight Constrained City DistanceSource: IFEU, SGKV 2002 13
  14. 14. Impact More Pronounced in Urban Setting Bus Example Physical resistances have an impact on Heavier buses consume more fuel in urban areas vehicle fuel efficiency and mass of the vehicle is a significant factor 3. Gradient Resistance FSt = m. g. sin a G = m. g. Lightweighting will enhance fuel consumption Impact is more pronounced in urban settingSource: IFEU, Alcoa 14
  15. 15. Rolling Resistance Lab Test• Research conducted by third-party firm (Smithers)• Tested to SAE spec and followed U.S. EPA Smartway protocol• Five test runs completed at varying loads and tire pressures 15
  16. 16. Light Weight Pays Fuel Economy Dividends An aluminum wheel can improve tire rolling resistance by up to 3% over a comparable size steel wheelSource: Smithers Scientific Services 16
  17. 17. Light Weight Pays Fuel Economy Dividends 40 Steel 35 Aluminum Rolling Resistance (lbs) 30 25 3% reduction in rolling resistance equates to 20 1% fuel savings reduction in rolling resistance 3% equates to 1% fuel savings 15 10 3000 3500 4000 4500 5000 5500 6000 6500 7000 Load (lbs)Source: Smithers Scientific Services 17
  18. 18. Major Tire Manufacturer Simulator Data Fuel Economy Improvement Per 10% Weight Save 9.0% 8.4% 8.0% 7.0% 6.7% 6.3% 6.0% Percent Improvement 5.0% 4.0% 3.0% 2.0% 1.0% 0.0% Medium Duty Heavy Duty Bus Base Weight 16,340 36,312 24,511 Drive Cycle HTUF Regional HTUFSource: Major Tire Manufacturer 18
  19. 19. China Bus Project: Real World Success Weight 6% Fuel 50 tons of CO2 Reduction of Economy Lifetime 1,400 kg (12%) Improvement Value – Ecological Space Frame Extrusions • Reduction in CO2 emissions • Reduced road surface wear and tear Value – Financial • 6% less fuel • Maintenance savings (tires, Wheel brakes, suspension) Body Panel • Improved corrosion resistance • Payback of 2-3 yearsSource: Alcoa 19
  20. 20. IAI Transport Model Illustrates Potential CO2 Savings from Lightweighting User Input Output Specifications of Final energy savings vehicles and through lightweighting components CO2 equivalent savings Customer scrap thought lighweighting generation IAI/EAA/AA Carbon footprints of Fuel/electricity consumption Transport aluminum and competing material during use Lifecycle Vehicle recycling Model Industry Inputs CO2 equivalents Final energy Aluminum production date Source: IAI Study 2008Source: IAI 20
  21. 21. IAI: Aluminum Helps Reduce CO2 • Auto aluminum already Specific Savings (Tons of CO2 per ton of w eight save) saving 300 million metric tons of CO2 annually 60 53 • Including CO2 impact of 50 aluminum production 40 28 • Use-phase savings far 30 23 18 outweigh production CO2 20 generation 10 3 0 • Recycled aluminum uses Constrained Constrained Bus - Urban Car Suburban Bus - Truck - Truck - Volume Weight 95% less energy Potential Weight Savings: 3,000-3,500 lbs. 3,500-4,500 lbs 300-500 lbsSource: IFEU, 2003 21
  22. 22. Aluminum is a Part of the SolutionMore Payload AND Lower Costs• One ton of weight reduction = up to 2,000 gallons of diesel per year Global CO2 Sources• Lower maintenance costs• Lower tire and brake costsHigher residual value and durability• Corrosion resistant parts last longerReduced Lifetime CO2 Emissions• Save 18 tons of CO2 for every ton of aluminum you add to your fleetReduced dependence on imported oilInfinitely recyclable 22
  23. 23. Questions? 23
  24. 24. The Aluminum AdvantageExploring Commercial Vehicle Applications Randall Scheps Chairman, The Aluminum Association’s Auto & Light Truck GroupMarketing Director, Alcoa Ground Transportation www.autoaluminum.org

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