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Growth & Development Trends of Automotive
Aluminum
Randall SchepsChairman, The Aluminum Association’s Transportation Group
Marketing Director – Automotive
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Who We Are
AluminumInTransportation.org
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Aluminum Builds a Better Vehicle
Reduced Emissions
Mass Reduction
Enhanced Performance
Improved Safety
Better Fuel Economy
Infinitely Recyclable
AluminumInTransportation.org
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“Based on our current understanding, we believe we’re
approaching the practical limits of the application of high-strength
steels,” says Frank Paluch, senior vice president at Honda R&D Americas at the International
Automotive Body Congress.
OEMs Weigh in on WeightPlans to use more aluminum
to cut vehicle weight.BMW, Reuters
Audi relies on aluminum… to achieve benefits of down
weighting as seen in the 2011 A8, such as a 25% increase in body stiffness, while reducing
weight by up to 20%.Audi/ATG, Joint press release
AluminumInTransportation.org
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Secondary Objective
Estimate “most likely” material mix through 2025
North American
Aluminum Use Survey Conducted by Ducker Worldwide
Primary Objective
Accurate estimate of 2012 light vehicle aluminum content
AluminumInTransportation.org
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Aluminum Content in 2012
125
14
23
24
49
60
69
70
88
89
112
115
126
130
371
516
588
636
785
790
0 100 200 300 400 500 600 700 800 900
All Other Compnents
Drive Shafts & Yokes
IP Structure
Cradles & Crossmembers
Engine Mounts
Other Steering
Differential Carriers
Bumpers
Transfer Cases
Control Arms & Links
Intake Manifolds
Steering Knuckles
Closures
Brake Parts
Other Engine
Heat Transfer
Cylinder Heads
Cylinder Blocks
Transmissions
Wheels
Millions of Pounds
AluminumInTransportation.org
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Aluminum Share
Expected to Double
Pe
rc
en
t o
f M
ate
ria
l M
ix
Source: Ducker Worldwide 2011
AluminumInTransportation.org
34% 35% 38%
58% 54% 46%
8% 11% 16%
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
2008 2015 2025
Aluminum
Steel
All OtherMaterials
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40 Years of Uninterrupted Growth
0
100
200
300
400
500
600
1975
1980
1985
1990
1995
2000
2005
2010
2015
2020
2025
Po
un
ds
pe
r V
eh
icle
2012: 343 lbs
Average increase of 7 lbs per year for 35 years
The trend line continues
to be supported by new aluminum
applications
AluminumInTransportation.org
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Content Growth 2009-2012
1%
3%
3%
3%
5%
10%
16%
19%
58%
0% 10% 20% 30% 40% 50% 60% 70%
Heat Transfer
Engine
Transmission & Driveline
Wheels & Brakes
Average Increase
Steering
Suspension
Crossmembers
Body, Bumper & Closure
Total Pounds
(over 50% from closures)
AluminumInTransportation.org
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Growth: Hoods, Trunks, Doors & Bumpers
12
10
6
3 2 3
58
10 11 121
4
8
11
0
5
10
15
20
25
2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015
Po
un
ds
pe
r V
eh
icle
Pounds per Vehicle New Applications(Primarily body, bumper & closure components)
AluminumInTransportation.org
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Aluminum is a
Cost Effective Solution
Cost Dollar/PoundSaved
Primary $2.00
Secondary ($1.82)
Net Cost $0.18
Average Cost of Direct Weight Savings
Increased use of aluminum is necessary and cost
effective in achieving 400 lb weight reduction by 2025
AluminumInTransportation.org
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Aluminum is a Safe Solution
Downweighting is necessary to meet demands without
sacrificing safety or functionality.
Pound for pound aluminum can absorb
two times the energy in a crash compared to steel.
Aluminum provides benefits that span
many aspects of design, including providing stronger, safer, more durable
vehicles.
According to a study conducted by the Univ. of Aachen, aluminum has a ~40% weight
reduction potential. Steel has ~11%.
AluminumInTransportation.org
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OEMs efforts to meet 35.5 mpg by 2016 coupled with the uncertainty surrounding the fuel economy standards beyond
2016 has caused a flurry of down weighting activity in the last two years.
OEMs don’t want expensive alternative powertrains to be forced on consumers, but they see the commercial and political value of saving weight.
2025 – Average vehicle will get lighter by 400 lbs- Aluminum: sheet & extrusions/closures, body-in-white, bumper & suspension- AHSS
Aluminum will grow to 16% of curb weight- 2012 – 343 lbs / 2025 – 550 lbs- Industry added 200 lbs per vehicle from 1990 to 2012- Increase of 207 lbs in 13 years
The aluminum industry has the capacity to support an aluminum intensive fleet in 2017-2025.
Conclusions
AluminumInTransportation.org
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Q u e s t i o n s
Thank You
www.AluminumInTransportation.org