Alcoa Automotive

Autmotive aluminum gains on steel for the 39th year in a row.

2009-04-08T15:50:22-04:00

In the last 39 years, we've been through ups and downs in the market, environmental and political challenges, and more. But you can say one thing: the driving experience has just gotten better and better. Better mileage, better reliability, better features, more comfort, more safety, more fun.

Coincidentally, or perhaps not, aluminum content in cars has grown steadily too: year after year after year. That's the conclusion of a new study by Ducker Worldwide, sponsored by the Aluminum Association.

In 1970, aluminum accounted for 2.0% of vehicle curb weight. In 2009, aluminum's share quadrupled to 8.6%, and it's expected to scale up to 10.4% by 2020.

That's not really surprising. It has been this way since the Nixon administration. Each and every year, more pounds of aluminum go into passenger cars, and 2009 will be no exception.

What is surprising is the news about where the growth is and which cars are getting more aluminum: the Chevy Malibu, Honda Pilot and others in the economy section of the food chain. Aluminum solutions that first made Ferraris and Audis lighter, stronger, and faster are now adding safety, sustainability and fuel economy to the cars that mere mortals drive.

Today, the average vehicle in North America contains 326 pounds of aluminum. The lion's share of the poundage goes into big chunks of metal like engine blocks, transmission housings, and suspension and frame components. These parts were less likely candidates for aluminum substitution decades ago, but advances in design, alloy chemistry, and fabrication have made it easier and easier for cars to lighten up.

Who's the lightweight leader of the pack? Would you believe an SUV? The 2009 Honda Pilot is 10.2% aluminum by curb weight. It's also longer, taller and wider than previous Pilot models, without being heavier. Its gas mileage is what you'd expect from a Honda: at the top of its class. And it maintains a 5-star safety rating from NHTSA.

Which part of the world leads the trend? That would be North America, home of the SUV. Consumers' preference for these vehicles, combined with rising gas prices and increasing pressure to reduce emissions has made aluminum the answer for doing more with less. At the other end of the carbon footprint, lightweighting solutions that include aluminum are helping realize the goal of affordable ultra-high mileage in a new generation of hybrid vehicles.

The researchers who put this study together are confident that this trend will continue, and we'll be seeing an average of 376 pounds per vehicles, or 10.4% of curb weight, at the end of the next decade. Whatever the actual numbers, you can bet that as the world grows more urbanized and more fragile at the same time, the magic of aluminum in making transportation more sustainable will play a definite part.

This info was presented at an Aluminum Association webinar April , 2009. To find out how you can get a transcript, click here. Or else stay tuned to www.alcoa.com/auto. We'll be posting one there soon.

Aluminum sets content record again; vindicates my Honda Pilot

2009-03-26T11:54:33-04:00

The bottom line in the Aluminum Association's latest study on aluminum use in cars is not much of a surprise if you've been following the industry: this year, for just about the 40th year in a row, aluminum use in autos will reach an all-time high. And for the same great reason: there's no better way to boost fuel economy, safety, comfort, style and sustainability all at once than by swapping out heavier, less recyclable components for aluminum solutions.

One of the more interesting surprises is the new leadership in this trend: Honda and BMW have risen to the top in terms of aluminum content, passing GM and Nissan.

I keep trying to tell folks that my 2002 Pilot, now passing 105K miles on just its second set of brakes and tires, drives like a Beemer -- it just doesn't look like one.

Now I know why.

Here's a link to download an executive summary of the report.

The Aluminum Assocation will share the results live via webinar on April 7. Here's a link to register.

If you're in a hurry to green up a car design, you'll want to catch this webinar

2008-12-09T14:32:11-05:00

I'm listening to a presentation by the aluminum assocation on the benefits of aluminum in automotive design. As you may know, aluminum is lighter than steel, and can be substituted for steel in automotive design to reduce vehicle weight. This webinar will get you up to speed, so to speak. And you'll also find out where lightweighting will take you: bottom line, if you reduce the weight of a vehicle by 10%, you'll improve mileage by 3-4%. Lighter cars save fuel and emissions. What about safety, you might ask? Aluminum can improve safety by allowing you to design a bigger vehicle, with a bigger safety margin, without adding weight.

To those of us in the business, this is pretty everyday stuff. But if you're new to this thing ... or if you're a car designer in a hurry to green up your product, the scientific detail in this presentation will help you get the job done.

Here's a link to the Aluminum Association's web site, where they should be posting a recording of this event soon.

And here's a link to another great source of lightweighting ideas.