2009 dec.cv webinar
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TRANSCRIPT
The Aluminum Advantage
Commercial Vehicle Applications
An Aluminum Association Webinarwww.autoaluminum.org
Why We Are Here Today
2
• Share lessons learned for sustainable
transportation solutions to economic and
ecologic challenges
• Request feedback to direct research for
commercial vehicle industry
Today’s Agenda
• Introductions
• Background in lightweighting
• Aluminum in commercial vehicles
• Challenges
• Weight-savings potential
• Existing research and case studies
• Q & A
3
Introductions
4
Randall Scheps
ATG Chairman
Marketing Director of
Ground Transportation
Alcoa
Todd Summe
Division Manager
Product Design &
Development
Alcoa
Doug Richman
Vice President of
Engineering &
Technology
Kaiser Aluminum
Defining Who We Are
5
The Aluminum Association’s Aluminum Transportation Group (ATG)
The Aluminum Transportation
Group’s Mission
6
• Central resource for the
trucking and automotive
industries on aluminum
• Promote research and
programs highlighting
advantages of
lightweighting with
aluminum
www.autoaluminum.org
Did You Know?
• Aluminum is the most abundant metal in the
earth’s crust
• 73% of all aluminum produced since 1888 is
still in use today
• Recycled aluminum uses 95% less energy to
produce than primary output
• The aluminum industry has cut greenhouse
gas factory emissions per ton of aluminum
produced by 30% since 1990, and aims to be
carbon neutral by 2030
• Weight saving with aluminum has the potential
to reduce lifecycle CO2 emissions by 30 tons
and increase payload capacity by 3,300 lbs. in
weight-constrained heavy trucks 7
Aluminum Builds a Better
Vehicle
8
Reduced Emissions
Mass Reduction
Enhanced Performance Improved
Safety
Better Fuel Economy
Infinitely Recyclable
Lightweighting Lessons from
the Auto Sector
9
• Crash safety study
– Size not weight is a
better determinant of
automotive safety
• Powertrain study
– Consumers “paid
back” faster at the
pump when
automakers reduce
vehicle weight
Research Validates Benefits of
Lightweighting
• Vehicle weight reduction study
– Fuel economy improvement of 5-7% is expected with 10% weight reduction
• Cost study
– Impact of aluminum structure mass savings on weight and cost reduction of
powertrain and chassis systems reduces the cost premium
• Electric vehicle study
– Opting for high-strength, low-weight aluminum structures for plug-in electric and
hybrid vehicles can cut vehicle price overall by reducing the battery energy
requirements and the associated costs
• Growth study
– After nearly four decades – the percentage of aluminum content continues to
climb in light vehicles 10
Proven Benefits Lead to
Continuous Growth
11Source: Ducker 2009
North American Light Vehicle Aluminum
Content Continues to Climb
Upcoming Commercial Vehicle
Research
• Class 8 Commercial Tractor-Van Fuel Consumption Study with Ricardo
– Objective
• Quantify fuel consumption impact of weight reduction
– Methodology
• Analytical simulation
– Vehicle content
• Conventional construction; traditional lightweighting; potential future lightweight applications
– Evaluation loading
• GVW; ½ GCW; un-loaded
– Driving conditions
• EPA HWFET, WVU Interstate and HUDDS cycles
– Timing
• Publication expected Q1-201012
Challenges Facing the
Commercial Vehicle Industry
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• Rising energy costs
• Growing concern over
greenhouse gas emissions
• Federal mandates
continue to add weight to
heavy-duty vehicles
• Weak economy
Of the 83 million barrels of crude oil used per day,
trucks account for more than half of the oil used in
transportation and its share is projected to increase
Source: International Energy Outlook 2005; U.S. EIA
Why Aluminum for Commercial
Vehicles?
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THE VALUE PROPOSITION
• Increased cargo capacity – up
to 3,300 lbs.
• Reduced fuel consumption and
emissions
• Lower maintenance costs
• Improved durability
• Higher resale
10% weight reduction = up to a 5.5%
improvement in fuel economy for
Class 8 Trucks
Truck Owners See Value in
Lightweighting
15Source: Alcoa 2008, Q4 research
Aluminum Already on the Road
Increases Payload and Fuel Economy
16
Lightweighting Options
• Cab structure
• Forged aluminum wheels
• Hubs
• Frame cross members
• Fuel tanks
• Trailer side walls and structure
• Flatbeds
• Tank bodies
* Relative to base truck & box trailer
Weight-Savings Potential
1,500 lbs.*
3,500 lbs.
7,000 lbs.
Emerging Technologies Save
More Weight
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3,300 lbs. total weight savings potential(truck & box van)
Cab Rear Wall
Save 49 lbs.Doors
Save 20 lbs.
each
Frame Rails
Save 435 lbs.
Bogey X-Member
Save 38 lbs.
RR Door Surround
Save 150 lbs.
Landing Gear
Save 50 lbs.
Cab Floor
Save 56 lbs.
Slider Box
Save 150 lbs.
Cab Roof
Save 60 lbs.
Rear Door
Save 187 lbs.
Fifth Wheel
Save 100 lbs.
Research Supporting
Lightweighting with Aluminum
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• Potential Savings as a Result of Weight
Reduction (IFEU Heidelberg 2003)
• Impact of Weight on Rolling Resistance
and Fuel Economy (Smithers 2009)
• Improving Sustainability in the Transport
Sector via Weight Reduction and
Application of Aluminum (IAI 2006)
• Case Study: China Bus Project (Alcoa
2008)
IFEU Heidelberg Research
Findings
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• Results based on real-
world experience of truck
OEMs
• Weight is a factor in truck
and bus fuel economy
• Trucks and buses
represent a large potential
fuel savings
• Duty-cycle dependant
Source: IFEU, SGKV 2002
27 25
62
2025
0
10
20
30
40
50
60
70
Lifetime Primary Energy Savings (GJ/100kg)
Car
(gasoline)
Long
Distance
Bus
City BusCar
(diesel)
Articulated
Truck
Road Vehicles
Estimated Fuel Economy Benefit from
10% Weight Reduction
20Source: IFEU, SGKV 2002
Aluminum Wheels Pay Fuel
Economy Dividends
21Source: Smithers Scientific Services
3% reduction in rolling resistance = 1% fuel savings
3%
Aluminum Helps Reduce CO2
22Source: Alcoa
8 16
1170 1106
0
200
400
600
800
1000
1200
1400
Steel Intense Truck
Aluminum Intense Truck
Me
ga
To
ns
of
CO
2eLifecycle CO2 Equivalent (CO2e)
Steel vs. Aluminum
CO2 Generated in Use of the Truck **
CO2 Generated in Material Production
** Assumes 10% weight save
5% less lifecycle CO2
Aluminum Helps Reduce CO2
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Specif ic Savings
(Tons of CO2 per ton of w eight save)
28
1823
3
53
0
10
20
30
40
50
60B
us -
Urb
an
Bus -
Suburb
an
Tru
ck -
Weig
ht
Constr
ain
ed
Tru
ck -
Volu
me
Constr
ain
ed
Car
Source: IFEU, 2003
Specific CO2 Savings Per Ton of Weight Save
30 tons CO2 lifecycle
savings
To
ns o
f C
O2
Available Modeling Tools
• Improving Sustainability in the Transport
Sector Through Weight Reduction and
the Application of Aluminium - Model
– Calculate energy savings from
lightweighting with aluminum
– Developed inline with ISO 14000
environmental management standards
– http://www.world-
aluminium.org/Downloads/Publications/M
ost%20recent
• CalcuLighterTM
– Calculate potential ROI by switching to
aluminum wheels
– http://www.alcoa.com/alcoawheels/north_
america/en/calculighter.asp
24Source: IAI and Alcoa
China Bus Project: Real World
Success
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• Value – Ecological
• Reduction in CO2
emissions
• Reduced road surface
wear and tear
• Value – Financial
• Less fuel
• Maintenance savings
(tires, brakes, suspension)
• Improved corrosion
resistance
• Payback of 2-3 years
Weight
Reduction of
1,400 kg (12%)
>6% Fuel
Economy
Improvement
50 Tons of
CO2 Lifetime
Spaceframe
Extrusions
Wheel
Body Panel
Source: Alcoa
Aluminum is a Part of the
Solution
26
• More payload AND lower costs
– One ton of weight reduction = up to
588 gallons of diesel per year
– Carry more cargo
– Lower maintenance costs
• Improved fuel economy
– 10% weight reduction = up to a
5.5% improvement in fuel economy
for Class 8 Truck
• Reduced lifetime CO2 emissions
– Save 18 tons of CO2 for every ton
of aluminum you add to your fleet
Get Involved
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• Heavy Duty Manufacturers Association (HDMA) Strategic Energy Council
formed within the Motor & Equipment Manufacturers Association (MEMA)
• Goals
• Improve SmartWaySM Transport program
• Influence Congress on energy-related legislation affecting the commercial vehicle
supplier industry
• Join HDMA today
• Contact:
Catherine Boland, Director of Government Relations
Phone: 202-312-9241
E-mail: [email protected]
Source: MEMA and EPA.gov
Contact Us
For more information or to
download this presentation
Visit www.autoaluminum.org
or
E-mail [email protected]
28
Question & Answer
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Please submit any questions through the question box on your screen
The Aluminum Advantage
Commercial Vehicle Applications
An Aluminum Association Webinarwww.autoaluminum.org