The document discusses trends in the increased use of aluminum in automotive applications to reduce vehicle weight. It notes that aluminum use has grown by an average of 7 pounds per year over the last 40 years. OEMs are looking to use more aluminum to cut 400 pounds from average vehicle weight by 2025 in order to meet fuel economy standards. Aluminum content is expected to double from the current 16% of curb weight to account for 550 pounds per vehicle by 2025.

1. Growth & Development
Trends of Automotive
Aluminum
Randall Scheps
Chairman, The Aluminum Association’s Transportation Group
Marketing Director – Automotive
1

2. Who We Are
2
AluminumInTransportation.org

3. Aluminum Builds a Better Vehicle
Mass Better Fuel
Reduction Economy
Infinitely
Recyclable Reduced
Emissions
Improved
Enhanced Safety
Performance
3
AluminumInTransportation.org

4. OEMs Weigh in on Weight
Plans 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 “Based on our current
body stiffness, while reducing understanding, we believe we’re
weight by up to 20%. approaching the practical limits of
Audi/ATG, Joint press release the application of high-strength
steels,” says Frank Paluch, senior
vice president at Honda R&D
Americas at the International
Automotive Body Congress.
4
AluminumInTransportation.org

5. North American
Aluminum Use Survey
Conducted by Ducker Worldwide
Primary Objective
Accurate estimate of 2012 light
vehicle aluminum content
Secondary Objective
Estimate “most likely” material mix
through 2025
5
AluminumInTransportation.org

6. Aluminum Content in 2012
Wheels 790
Transmissions 785
Cylinder Blocks 636
Cylinder Heads 588
Heat Transfer 516
Other Engine 371
Brake Parts 130
Closures 126
Steering Knuckles 115
Intake Manifolds 112
Control Arms & Links 89
Transfer Cases 88
Bumpers 70
Differential Carriers 69
Other Steering 60
Engine Mounts 49
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
6
AluminumInTransportation.org

7. Aluminum Share
Expected to Double
100%
8% 11%
90% 16%
Percent of Material Mix
80%
70% Aluminum
60% 58% 54% 46%
50% Steel
40%
30% All Other
20% 34% 35% 38% Materials
10%
0%
2008 2015 2025 Source: Ducker Worldwide 2011
7
AluminumInTransportation.org

8. 40 Years of Uninterrupted
600
Growth
The trend line
Pounds per Vehicle
continues
500
to be supported by 2012: 343 lbs
new aluminum
400 applications
300 Average increase of 7 lbs
per year for 35 years
200
100
0
1975
1980
1985
1990
1995
2000
2005
2010
2015
2020
2025
8
AluminumInTransportation.org

9. Content Growth 2009-2012
(over 50%
Body, Bumper & Closure 58% 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
9
AluminumInTransportation.org

10. Growth: Hoods, Trunks,
Doors & Bumpers
25
Pounds per Vehicle
20
Pounds per Vehicle New Applications 11
(Primarily body, bumper
& closure components) 8
15
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
10
AluminumInTransportation.org

11. Aluminum is a
Cost Effective Solution
Increased use of aluminum
is necessary and cost
effective in achieving 400 lb Average Cost of Direct
weight reduction by 2025 Weight Savings
Cost Dollar/Pound
Saved
Primary $2.00
Secondary ($1.82)
Net Cost $0.18
11
AluminumInTransportation.org

12. Aluminum is a Safe Solution
Downweighting is Pound for pound
necessary to meet aluminum can absorb
demands without two times the
sacrificing safety or energy in a crash
functionality. compared to steel.
Aluminum provides According to a study
benefits that span conducted by the Univ.
many aspects of design, of Aachen, aluminum
including providing has a ~40% weight
stronger, safer, reduction potential.
more durable Steel has ~11%.
vehicles.
12
AluminumInTransportation.org

13. Conclusions
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.
13
AluminumInTransportation.org

14. Thank You
Questions
www.AluminumInTransportation.org
14