1. The Changing Make Up of Automobiles
Survey Results: Aluminum Usage by
North American Automakers
An Aluminum Association Webinar
September 23, 2011
www.aluminumintransportation.org 1

2. Defining Who We Are
The Aluminum Association’s Aluminum Transportation Group (ATG)
www.aluminumintransportation.org 2

3. Introductions
Randall Scheps Doug Richman
ATG Chairman ATG Executive and
Marketing Director Technical Committees
Alcoa, Inc. Vice President
Engineering & Technology
Kaiser Aluminum
www.aluminumintransportation.org 3

4. Why We are Here Today
• Promote a holistic, multi-material approach combining
strong lightweight materials like aluminum with smart
design and advanced powertrains
• Agenda
– Benefits of Lightweighting with Aluminum
– Results of 2011 Ducker Survey of Automakers on Aluminum
Content in Passenger Vehicles
– Q&A
www.aluminumintransportation.org 4

5. Vehicle Make-Up Is Changing
• Two main factors
leading automakers
to rethink vehicle
design
– Consumer demand and
desire for increased fuel
efficiency coupled with a
need to continuously
improve safety, function
and comfort
– New, stringent fuel
economy standards
www.aluminumintransportation.org 5

6. Aluminum Builds a Better Vehicle
Mass Better Fuel
Reduction Economy
Infinitely Reduced
Recyclable Emissions
Enhanced Improved
Performance Safety
www.aluminumintransportation.org 6

7. Automakers Confirm Plans to
Downweight
• Audi: To migrate aspects of the ASF® technology currently in the A8
to higher volume vehicles like the A6
• BMW: To use more aluminum to cut weight
• Ford: To trim 250-750 lbs. out of each model year
• GM: To trim 500 lbs by 2016 and 1,000 lbs. by 2020
• Jaguar Land Rover: To construct all future vehicles with aluminum
bodies
• Nissan: To reduce 15% of vehicle weight
7

8. Aluminum-Intensive Vehicles Today:
Maintained Size, Decreased Weight
2011 Audi TT
Roadster ASF 58%
• Better fuel economy
aluminum and Coupe
ASF 69% aluminum
Source: Audi • No downsizing
2011 Jaguar XJ
All aluminum • Improved handling
body structure
saves 150kg
compared to its
competitors
• Lower lifetime CO2
Source: Jaguar
• Improved safety
2011 Audi A8
ASF all aluminum
except the B-pillars
Source: Audi
• Enables cost savings
www.aluminumintransportation.org 8

9. Aluminum in 2012 North
American Light Vehicles
Survey of North American
Automakers by Ducker Worldwide
www.aluminumintransportation.org 9

10. Survey Objectives
• Primary Objective
– Accurate estimate of 2012 North American
light vehicle aluminum content
• Secondary Objective
– Estimate “most likely” material mix through
2025
www.aluminumintransportation.org 10

11. Methodology
• Detailed analysis of aluminum content
– Segment
– Original Equipment Manufacturers (OEMs)
– More than 90 components
• Iron, steel, aluminum and magnesium
• All product forms – cast, rolled and
extruded
• Interviews conducted with automotive
engineers
– Major OEMs
– Tier One suppliers
– Material producers
www.aluminumintransportation.org 11

12. Core Findings
www.aluminumintransportation.org 12

13. 40 Years of Uninterrupted Growth
Aluminum Content – Pounds Per Vehicle
600
2012
500
Pounds per Vehicle
343 lbs per vehicle
400
Average increase of 7 lbs per year
for 35 years
300
200
100
0
1975
1980
1985
1990
1995
2000
2005
2010
2015
2020
2025
www.aluminumintransportation.org 13
Source: Ducker Worldwide 2011

14. Aluminum Share Expected to Double
100%
8% 11%
90% 16%
80%
Percent of Material Mix
70% 42% 38% 30%
Aluminum
60%
50% Flat Rolled Steel
40%
30% All Other
50% 51% 54% Materials
20%
10%
0%
2008 2015 2025
www.aluminumintransportation.org 14
Source: Ducker Worldwide 2011

15. Component Analysis
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16. Aluminum Content in 2012
Wheels 790
Transmissions 785
Cylinder Blocks 636
Cylinder Heads 588 Nearly 80% of engine blocks
Heat Transfer 516 in 2012 are aluminum
Other Engine 371
Brake Parts 130
Closures 126
Steering Knuckles 115 Record aluminum
Intake Manifolds 112
content in 2012:
Control Arms & Links 89
Transfer Cases 88
•Engine Blocks
Bumpers 70 •Closures
Differential Carriers 69 •Bumpers
Other Steering 60 •Steering Knuckles
Engine Mounts 49
•IP Structures
Cradles & Crossmembers 24
IP Structure 23
Drive Shafts & Yokes 14
All Other Compnents 125
0 100 200 300 400 500 600 700 800 900
Millions of Pounds
www.aluminumintransportation.org 16
Source: Ducker Worldwide 2011

17. Aluminum Penetration for Key
Components in 2012
Heat Exchangers 100%
Transmission 100%
Cylinder Heads 98%
Cylinder Blocks 80%
Wheels 70%
Steering Knuckles 45%
Control Arms 40%
Hoods 31%
Bumpers 20%
0% 20% 40% 60% 80% 100%
Total Components
www.aluminumintransportation.org 17

18. 2009-2012 Aluminum Content Growth
Body, Bumper & Closure 58% (over 50% from closures)
Crossmembers 19%
Suspension 16%
Steering 10%
Average Increase 5%
Wheels & Brakes 3%
Transmission & Driveline 3%
Engine 3%
Heat Transfer 1%
0% 10% 20% 30% 40% 50% 60% 70%
Total Pounds
www.aluminumintransportation.org 18
Source: Ducker Worldwide 2011

19. 50% Percent of Knuckles
Aluminum in 2012
60%
50%
50%
39%
40%
30%
30%
17% 19%
20%
10%
1%
0%
www.aluminumintransportation.org 19
Source: Ducker Worldwide 2009 and 2011

20. 20% of All Bumpers Aluminum in 2012
25.0%
20%
20.0%
15.0%
11%
10.0% 9%
7%
5% 6%
5.0%
0.0%
www.aluminumintransportation.org 20
Source: Ducker Worldwide 2009 and 2011

21. Aluminum Hood Growth
35%
Over 30% 31%
30% of all the hoods will
be aluminum 23%
25%
in 2012
20% 19%
14%
15%
10%
10%
6%
5%
0%
www.aluminumintransportation.org 21
Source: Ducker Worldwide 2011

22. Evolution of Body-in-White Construction
Optimized
Aluminum Multi-Material
High Strength Aluminum
Steel High Strength Alloy
Aluminum Intensive Vehicle
Steel & Aluminum Hybrid – Majority
Aluminum
Steel & Aluminum Hybrid – Majority Steel
Today 2015 2020 2025
www.aluminumintransportation.org 22
Source: Alcoa

23. Segment Analysis
www.aluminumintransportation.org 23

24. E Segment Vehicles Leader in Total
Aluminum Pounds Per Segment
2012 Aluminum Pounds per Segment
421
450
363
Aluminum Pounds per Vehicle
400 354 343
329
350 275
300 229
250
200
150
100
50
0
www.aluminumintransportation.org 24
Source: Ducker Worldwide 2011

25. Aluminum Percent of Curb Weight
by Segment
12.0%
9.6% 10.0% 9.7%
10.0% 8.5% 8.7% 9.0%
8.0% 6.8%
6.0%
4.0%
2.0%
0.0%
www.aluminumintransportation.org 25
Source: Ducker Worldwide 2011

26. North American Aluminum
Content Leaders
Honda content leader as percent of
GM content leader at 366 lbs per vehicle
curb weight at 10.7% per vehicle
2012 Chevrolet Malibu 2012 Honda CRV
Aluminum Content 385 Lbs Aluminum Content 10.9%
Source: General Motors Media Site Source: Honda Media Site
www.aluminumintransportation.org 26
Source: Ducker Worldwide 2011

27. Top Aluminum Content Vehicles
2012 Ford Escape
Aluminum content 10.9%
• Newer vehicles have average Source: Ford Media Site
aluminum content 10.4% of
vehicle curb weight (vs. 9%)
- Cadillac ATS - Ford Fusion
- Cadillac XTS - Honda Accord
- Chevrolet Malibu - Honda Civic
- Chrysler 300 - Honda CR-V 2012 Chrysler 300
Aluminum content 10.6%
- Chrysler/Fiat C - Lincoln MKZ Source: Chrysler Media Site
Sedan - Mercedes-Benz
- Fiat 500 ML-Class
- Ford Explorer - Nissan Altima 2012 Nissan Altima
- Ford Escape - Toyota Avalon Aluminum content 11.1%
Source: Nissan Media Site
www.aluminumintransportation.org 27
Source: Ducker Worldwide 2011

28. Ducker Worldwide
Aluminum Forecast
www.aluminumintransportation.org 28

29. Aluminum Growth Projected to Reach
400 Pounds Per Vehicle by 2015/2016
Aluminum Content – Pounds Per Vehicle
600
2015
400 lbs per vehicle
2012
500
Pounds per Vehicle
343 lbs per vehicle
The trend line continues
400
to be supported by
new aluminum applications
300
200
100
0
1975
1980
1985
1990
1995
2000
2005
2010
2015
2020
2025
www.aluminumintransportation.org 29
Source: Ducker Worldwide 2011

30. New Applications Required to
Achieve 2015/2016 Growth Scenario
North American Light Vehicle Aluminum
Content Increases
25
Pounds per Vehicle
20
Pounds per Vehicle New Applications 11
(Primarily body, bumper 8
15 and closure components)
4
10
12 1 12
10 11
10
5 6 8
5
3 2 3
0
2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015
www.aluminumintransportation.org 30
Source: Ducker Worldwide 2011

31. Ducker Long Term Forecast
Assumptions
• 51 MPG 2025* fuel economy target
• 10% average weight reduction
• 44% HEVs
• 1 sq. ft. (2% from 2008 EPA base year)
footprint reduction
* Average based on 54.5 MPG for cars and at least 46.5 MPG for light trucks
www.aluminumintransportation.org 31
Source: Ducker Worldwide 2011

32. Significant Growth For Aluminum
Predicted by 2025
Aluminum Content – Pounds Per Vehicle 2025
550 lbs per vehicle
600
2012
500
Pounds per Vehicle
343 lbs per vehicle
The trend line continues
400
to be supported by
new aluminum applications
300
200
100
0
1975
1980
1985
1990
1995
2000
2005
2010
2015
2020
2025
www.aluminumintransportation.org 32
Source: Ducker Worldwide 2011

33. Aluminum Pounds Per Truck
Predicted to Increase Dramatically
800 Average Aluminum Pounds Per Vehicle
Car vs. Light Truck 671
700 650
607 629
585
600
513 528
485 498
500 450 459
420
373 394
400
300
200
100
0
2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023 2024 2025
Car Truck
www.aluminumintransportation.org 33
Source: Ducker Worldwide 2011

34. Average Vehicle Must Lose Over
400 Lbs of Curb Weight by 2025
Sources of Weight Savings
for 4% CAGR for MPG
Add 225 lbs. of AHSS
Add 250 lbs. of
aluminum
70, 17% 80, 20%
Add 250 lbs. ofof
Add 225 lbs. AHSS
replacing mild steel
Aluminum
Weight compounding
78, 19% effect Compounding
Weight
Effect
1 sq. ft. footprint
180, 44%
reductionFootprint One
Reduce
Square Foot
408 lbs. saved or 10% over
2008 (NHTSA/EPA base year)
www.aluminumintransportation.org 34
Source: Ducker Worldwide 2011

35. Average Net Cost of Direct and
Indirect Weight Reduction
• Increased use of aluminum necessary and cost effective
in achieving 400 lb weight reduction by 2025
Average Cost of Direct Weight Savings
Cost Dollar/Pound
Saved
Primary $2.00
Secondary ($1.82)
Net Cost $0.18
www.aluminumintransportation.org 35
Source: Ducker Worldwide 2011 & IBIS 2005

36. Ducker Study Conclusions
• Consumer demand and fuel economy regulations are
driving a dramatic increase in aluminum usage
– Weight savings from aluminum and AHSS for body parts
• Automakers working hard to improve fuel economy and
maintain or improve size, function, safety and comfort
• Weight reduction with aluminum is a cost effective part of
the solution
www.aluminumintransportation.org 36
Source: Ducker Worldwide 2011

37. Ducker Study Conclusions
• By 2025, the average vehicle will get lighter by 400 lbs.
– Aluminum and AHSS
– Aluminum
• Sheet , extrusions
• Closures, body-in-white, bumper, and suspension components
• Aluminum will grow to 16% of curb weight
– 343 pounds in 2012
– 550 pounds in 2025
– Increase of 207 lbs. in 13 years
– Industry added 200 lbs. per vehicle from 1990 to 2010
• This is a conservative forecast
www.aluminumintransportation.org 37
Source: Ducker Worldwide 2011

38. Question & Answer
Please submit questions through the box
that appears on your screen
For additional aluminum research in the areas of safety, cost,
alternative powertrains, growth and sustainability, to sign-up for
the ATG’s monthly newsletter and/or download this presentation,
please visit us online at www.aluminumintransportation.org or
e-mail atginfo@aluminum.org
Thank You
www.aluminumintransportation.org 38