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2009 oct sae_c_vpres


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2009 oct sae_c_vpres

  1. 1. The Aluminum Advantage Commercial Vehicle Applications Todd Summe Technical Committee, The Aluminum Association’s Aluminum Transportation GroupDivision Manager, Product Design & Development – Alcoa
  2. 2. Defining Who We Are 2 Session CV702
  3. 3. Our Mission• Central resource for the automotive industry on aluminum• Promote research and programs highlighting advantages• Expanding mission to include commercial vehicles 3 Session CV702
  4. 4. Aluminum Builds a Better Vehicle Mass Better Fuel Economy Reduction Infinitely Reduced Recyclable Emissions EnhancedPerformance Improved Safety 4 Session CV702
  5. 5. Research Validates Benefits of LightweighingASSOCIATION SPONSORED RESEARCH 15• Safety: Size vs. Weight (DRI 2004) 13• Vehicle Structure: Manufacturing Weight reduction & resizing % Fuel Economy Improvement 11 and Lifecycle Cost Analysis (IBIS 10% 6-7% 2005) 9• Improving Sustainability in the 7 Transport Sector Through Weight 5 Reduction and the Application of 3 Aluminum (IAI 2006) 1• Benefit Analysis: Use of Aluminum 0 5 10 15 20 25 Structures in Conjunction with % Weight Reduction Small Car - Resized Engine Mid Size Car - Resized Engine Small SUV - Resized Engine Alternative Powertrain Large SUV - Resized Engine Truck - Resized Engine Small Car - Baseline Engine Technologies in Automobiles (IBIS Mid Size Car - Baseline Engine Small SUV - Baseline Engine Large SUV - Baseline Engine Truck - Baseline Engine 2008)• Aluminum Growth Study (Ducker Impact of Vehicle Weight Reduction on Fuel Economy for 2009 & 2006) Various Vehicle Architectures (Ricardo 2007) 5 Session CV702
  6. 6. Validation Leads toContinuous Growth North American Light Vehicle Aluminum Content Continues to Climb Source: Ducker 2009 6 Session CV702
  7. 7. Why We Are Here Today• Apply our auto industry model to the commercial vehicle industry• Lightweighting with aluminum can help you tackle the challenges • Auto companies and other third-parties acknowledge aluminum’s value proposition will help them meet 2016 CAFE standards• Overview • Industry challenges • Value proposition • Weight saving benefits • Research and data 7 Session CV702
  8. 8. Challenges Facing 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 intransportation and its share is projected to increase Source: International Energy Outlook 2005; U.S. EIA 8 Session CV702
  9. 9. Why Aluminum for Commercial Vehicles?THE VALUE PROPOSITION• Increased payload• Lower maintenance costs• Reduced fuel consumption• Reduced greenhouse gas emissions• Improved durability According to the U.S. EPA, a 10% drop in• Higher resale value truck weight reduces fuel use between 5-10%• Infinitely recyclable 9 Session CV702
  10. 10. Truck Owners See Value in Lightweighting Source: Alcoa 2008, Q4 research 10 Session CV702
  11. 11. Aluminum Already on the Road• Cab structure• Trailer side walls and structure The average Class 8 Tractor today• Flatbeds/tippers/dump bodies contains 1,000 lbs. of aluminum• Forged aluminum wheels• Frame cross members• Coal trucks• Fifth wheel• Fuel tanks• HVAC components• Landing gear• Tank bodies• Bellhousing 11 Session CV702
  12. 12. How Much Weight is Being Saved? Tractor • Axle hubs = 120 lbs. • Centrifuse brake drums = 100 lbs. • Clutch housing = 50 lbs. • Front axle leaf springs = 70 lbs. Trailer • Roof posts = 75 lbs. • Floor joists = 300 lbs. • Upright posts = 600 lbs. Aluminum wheels on a tractor cansave 30 lbs. each for a total savings • Hubs and wheels = 900 lbs. of 300 lbs. Source: U.S. EPA Weight Reduction Fact Sheet 2004 12 Session CV702
  13. 13. Emerging Technologies Save More Weight 3,500 lbs. weight savings potential 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 Save 150 lbs. Frame Rails Cab X-Member Save 30 lbs. per Save 435 lbs. Save 38 lbs. wheel 13 Session CV702
  14. 14. Research Supporting Our Value Proposition• Potential Savings as a Result of Weight Reduction (IFEU Heidelberg 2003)• Improving Sustainability in the Transport Sector via Weight Reduction and Application of Aluminum (IAI 2006)• Case Study: China Bus Project (Alcoa 2008)• Impact of Weight on Rolling Resistance and Fuel Economy (Smithers 2009)• Simulator Data (Major Tire Manufacturer 2007 14 Session CV702
  15. 15. IFEU Heidelberg Research Findings• Results based on real- world 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 15 Session CV702
  16. 16. Estimated Fuel Economy Benefit from 10% Weight Reduction Source: IFEU, SGKV 2002 16 Session CV702
  17. 17. Impact More Pronounced in Urban Setting: Bus Example Physical resistances have an impact on vehicle fuel efficiency and mass of Duty cycle is important factor the vehicle is a significant factor 3. Gradient Resistance FSt = m. g. sin a G = m. g.Impact is more pronounced in urban setting 17 Source: IFEU, Alcoa Session CV702
  18. 18. China Bus Project: Real World Success Weight >6% Fuel 50 Tons of Reduction of Economy CO2 Lifetime 1,400 kg (12%) Improvement Value – Ecological Space Frame • Reduction in CO2 emissions Extrusions • Reduced road surface wear and tear Value – Financial • Less fuel • Maintenance savings (tires, brakes, suspension) • Improved corrosion resistance Wheel • Payback of 2-3 years Body Panel 18 Source: Alcoa Session CV702
  19. 19. Relevant Auto Study: Aluminum Adds Value to Alternative Powertrains 19 Source: IBIS Associates Session CV702
  20. 20. Aluminum Wheels Pay Fuel Economy Dividends An aluminum wheel can improve tire rolling resistance by up to 3% over a comparable size steel wheel 3% less rolling resistance =1% fuel savings Source: Smithers Scientific Services 20 Session CV702
  21. 21. Major Tire Manufacturer Simulator DataBase Weight 16,340 36,312 36,312Drive Cycle HTUF Regional HTUF Source: Major Tire Manufacturer 21 Session CV702
  22. 22. IAI Transport Model Illustrates Potential CO2 Savings from Lightweighting User Input Output Specifications Final energy savings of vehicles and through lightweighting components Customer CO2 equivalent savings 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 22 Session CV702
  23. 23. IAI: Aluminum Helps Reduce CO2 Specific Savings• Auto aluminum already (Tons of CO2 per ton of w eight save) saving 300 million metric tons of CO2 60 53 annually 50 40• Including CO2 impact of 28 aluminum production 30 18 23 20• Use-phase savings far 10 outweigh production 3 0 CO2 generation Constrained Constrained Bus - Urban Car Suburban Bus - Truck - Truck - Volume Weight• Recycled aluminum uses 95% less energy Potential Weight Savings: 3,000-3,500 lbs. 3,500-4,500 lbs. 300-500 lbs. Source: IFEU, 2003 23 Session CV702
  24. 24. Use-phase Savings Outweigh Production Energy GenerationGJoules Source: Alcoa – Automotive Example 24 Session CV702
  25. 25. Aluminum is a Part of the SolutionMore Payload AND Lower Costs• One ton of weight reduction = up to 588 gallons of diesel per year• 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 25 Session CV702
  26. 26. Help US so that we can help YOU Research topics Data gaps to fill 26 Session CV702
  27. 27. The Aluminum Advantage Commercial Vehicle Applications Todd Summe Technical Committee, The Aluminum Association’s Aluminum Transportation GroupDivision Manager, Product Design & Development – Alcoa