Uses of Aluminum in cars

Aluminum offers distinct performance advantages that help automakers build better cars and
trucks. That is why the auto industry is the fastest-growing customer for aluminum. In 2009,
aluminum content reached an all-time high at 8.6 percent of average vehicle curb weight,
continuing almost 40 years of uninterrupted growth in North America. Aluminum use is still
growing, largely due to its environmental, safety and driving performance advantages.

Environmental Advantage

 As automakers strive to reach CAFE standards, lightweighting will become vital to

increased fuel economy, especially when combined with hybrids, clean diesels and other
powertrain technologies.
 Recycling aluminum saves nearly 95 percent of the greenhouse gas emissions (CO2
equivalent) associated with primary aluminum production and requires only about 5
percent of the energy – a distinct advantage since nearly 60 percent of aluminum used on
today’s vehicles is sourced from recycled metal.
 A 5 to 7 percent fuel savings can be realized for every 10 percent weight reduction by
substituting lightweight aluminum for a heavier material.
 Increased use of aluminum has saved burning more than 84 billion liters of fuel since
1990.
 Nearly 90 percent of automotive aluminum currently is recovered and recycled.

Growth Advantage

 Today’s average vehicle in North America contains 340 pounds of aluminum, making it
the second most used material in vehicles.
 Aluminum’s use in light trucks, SUVs and minivans has tripled since 1991 due to its
environmental, safety and driving performance advantages. In the past decade, aluminum
use has doubled in cars.

Performance Advantage

 All other factors being equal, vehicles made lighter with aluminum can accelerate quicker
and require shorter stopping distances than heavier vehicles.
 Compared to heavier steel, aluminum can provide better stability and response, and
reduced noise, vibration and harshness (NVH) due to reduced vehicle weight combined
with high structural stiffness.
 Reducing weight with aluminum can decrease the slip angle between tires and the road
for any given turning situation, allowing a vehicle to respond more directly and safely to
steering inputs.
 The rigidity of aluminum’s structures puts drivers in touch with the road and provides
more rapid and precise control.

Safety Advantage
  Aluminum can absorb nearly twice as much crash energy as steel, and aluminum can be
designed to fold predictably during a crash, letting the vehicle – not its passengers –
absorb more of the crash forces.
 Since aluminum is lighter than steel, it can be used to maintain or even increase the size
and strength of a vehicle’s critical front- and back-end crumple zones without increasing
overall weight, or sacrificing occupant safety.
 Injuries in crashes involving SUVs and smaller vehicles can be reduced up to 26 percent
by using aluminum to extend the SUVs front/rear crush zone while cutting overall
weight.

Return On Investment

 Aluminum can compete successfully with other materials because of the advantages it
brings in primary and secondary weight savings, fuel savings, structural performance and
design flexibility.
 When considering primary and secondary weight savings, an aluminum-intensive vehicle
could save up to 17.6 percent curb-weight at a cost premium of just $103. This weight
saving translates into more than a 15 percent increase in average mileage per gallon.
 Substituting lightweight, high strength aluminum for steel can improve fuel economy at
just $30 per mile per gallon improvement.

Aluminum use in cars hits all-time high

March 24th, 2009 Carmakers and legislators have been duking it out for decades. As one side fights to
find new ways to lighten cars up, improve handling and efficiency, the other heaps on more and more
safety regulations and mandatory equipment until things eventually cancel out. But an undercurrent to the
progression toward more rigid, safer, and feature-packed vehicles over the last 40 years has been the
increasing use of aluminum. Surprisingly, despite the American public's taste for large vehicles, North
America leads the world in vehicular aluminum use, about 0.8% ahead of the world average of 7.8%. By
brand, Honda and BMW are leading the way in aluminum use, with about 340lb (154kg) of the metal in
each car on average. General Motors and Nissan had previously led the way, and still remain among the
leaders. Volkswagen and Hyundai are also among the brands steadily increasing their use of the
material. But where in the car is all of this aluminum going? Mostly into engine blocks, wheels,
suspension components and hoods. Almost 70% of all cars sold in North America now have aluminum
engine blocks, and over 22% feature aluminum hoods. The rate of growth in aluminum use isn't slowing,
either. Current estimates put the increase at about 4-5lb (roughly 2kg) per year, rising to about 300lb
(136kg) per vehicle by 2020. That's roughly 9.4% by weight, given the average 3,185lb (1,447kg) curb
weight of light vehicles. Some cars, like the Honda Insight pictured above, are also beginning to
incorporate even lighter materials including composite resins and carbon-fiber derivatives. The Insight, for
example, uses a composite resin material for its intake manifold, saving even more weight than an
equivalent aluminum part.2009 Honda Insight Hybrid
2009 honda insight hybrid 013
Enlarge Photo
Carmakers and legislators have been duking it out for decades. As one side fights to find new ways to
lighten cars up, improve handling and efficiency, the other heaps on more and more safety regulations
and mandatory equipment until things eventually cancel out. But an undercurrent to the progression
toward more rigid, safer, and feature-packed vehicles over the last 40 years has been the increasing use
of aluminum.

Surprisingly, despite the American public's taste for large vehicles, North America leads the world in
vehicular aluminum use, about 0.8% ahead of the world average of 7.8%.

By brand, Honda and BMW are leading the way in aluminum use, with about 340lb (154kg) of the metal in
each car on average. General Motors and Nissan had previously led the way, and still remain among the
leaders. Volkswagen and Hyundai are also among the brands steadily increasing their use of the
material.

But where in the car is all of this aluminum going? Mostly into engine blocks, wheels, suspension
components and hoods. Almost 70% of all cars sold in North America now have aluminum engine blocks,
and over 22% feature aluminum hoods.

The rate of growth in aluminum use isn't slowing, either. Current estimates put the increase at about 4-5lb
(roughly 2kg) per year, rising to about 300lb (136kg) per vehicle by 2020. That's roughly 9.4% by weight,
given the average 3,185lb (1,447kg) curb weight of light vehicles.

Some cars, like the Honda Insight pictured above, are also beginning to incorporate even lighter materials
including composite resins and carbon-fiber derivatives. The Insight, for example, uses a composite resin
material for its intake manifold, saving even more weight than an equivalent aluminum part.
2009 Honda Insight Hybrid
The amount of aluminum used in new European cars has risen from 110 lbs. (50 kg) in 1990 to 291 lbs.
(132 kg) in 2005, and the achieved weight savings will lead to an annual fuel savings of 1 billion liters,
according to a recently released study.

U.S. automobile producers recently have seen slightly lower increases, according to reports by
Stratecasts Inc., Estero, Fla. The casting forecaster estimates that U.S. automobiles currently include an
average of 260 lbs. of aluminum castings per car and light truck. Between 2004 and 2006, domestic
aluminum automotive casting shipments have shown a 9% jump. Those increases should continue
through 2010.

"Aluminum, magnesium and plastics are to replace gray iron parts to facilitate compliance with Federal
Clean Air Act legislation and regulations," says the Stratecasts report.
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By 2014, U.S.-produced automobiles are forecast to have 280 lbs. of aluminum castings per car.

The amount of aluminum per automobile in Europe is expected to grow another 55 lbs. (25 kg) by
2010.

Already, in 2005, 2 million metric tons of aluminum components were put on European roads in
new passenger cars. In addition to preserving fuel, the achieved weight savings will lead to
roughly 40 million metric tons of C[O.sub.2] emissions over the lifespan of the vehicles.

The study, by Knibb, Gormezano & Partners (KGP), Castle Donington, Derbyshire, England, in
cooperation with the European Aluminium Association (EAA), includes data from automotive
companies and suppliers, EAA member companies and past data from KGP. The study is based
on the analysis of the 15 million cars produced in Europe in 2005 and investigates 20 body
components, 17 chassis and suspension components and 25 powertrain components.

The study focuses on different aluminum castings, extrusions, forgings and sheets. In the car
body, the largest quantities of components made from aluminum are in air conditioning systems,
bonnets, bumper beams and steering columns. Aluminum parts in the chassis and suspension
section of cars are mainly wheels, suspension arms and steering components. Cylinder heads,
cylinder blocks, engine covers, pumps and radiators represent the majority of aluminum
components in the drivetrain of new cars. Today, a growing amount of aluminum is being used in
closures, body structure and chassis applications.

In the U.S. going forward, Stratecasts forecasts that automotive component producers can expect
that 50% of their parts will be die cast by 2014. The remainder will be cast in permanent mold and
green sand.

"As 100 kg (220 lbs.) of aluminum on a car can reduce C[O.sub.2] emissions per kilometer by 9
grams (0.3 ounces), aluminum as material for light-weighting cars has a clear advantage," said a
press release issued by the European researchers. "With the continual introduction of further
advantages in the design and manufacturing processes, the trend to increase the amount of
aluminum per car will continue. Aluminum will certainly play an important role in future
generations of sustainable cars."