Auto Aluminum Usage Hits All-Time High, Expected to Aggressively Accelerate

Automakers are accelerating their shift to aluminum away from other materials for new car and light truck construction, as they seek to safely and cost-effectively lower the weight of vehicles according to a new survey of North American automakers conducted by Ducker Worldwide. The survey of automakers indicates that since lighter vehicles get better fuel economy with fewer emissions, aluminum is already the leading material in the engine and wheel markets and is fast-gaining market share in hoods, trunks and doors. The survey estimates automakers will increase their use of aluminum from 327 pounds in 2009 to 550 pounds in 2025.

The also shows continued growth in automaker's overall use of aluminum reaches an all-time high of 343 pounds per vehicle in 2012 - up five percent from 327 pounds in 2009. Aluminum usage has increased every year for nearly 40 years. Longer term, the report predicts aluminum is expected to double its share of the average automotive materials mix to 16 percent by 2025(1) with future cars and light trucks reaching a predicted average of 550 pounds of automotive aluminum per vehicle. As the Obama Administration considers stricter fuel economy regulations, automakers are expected to lower the overall weight of vehicles by approximately 400 pounds per vehicle, and as aluminum use increases, the mix percent is expected to double.

"This new survey of automakers makes clear that in terms of new vehicle designs to greatly step up fuel economy…aluminum's time has come," said Randall Scheps, Chairman of the Aluminum Association's Aluminum Transportation Group and Marketing Director at Alcoa, Inc. "Cars and trucks will get lighter and more efficient, but thanks to aluminum, they won't have to get smaller or less safe."

"We are fast-entering a transition stage to more holistic vehicle design approaches premised on greater use of lighter, stronger and more crash absorbent aluminum alloys replacing less efficient iron and steel. Vehicles with their size maintained, but downweighted with aluminum are inherently more efficient than heavier ones," said Scheps.

"Most importantly in this holistic approach, downweighting is actually an enabler of cost savings across the vehicle by accommodating downsized powertrains and parts consolidation - all without sacrificing safety or performance. A lighter car can allow for a smaller, less expensive drive train and generate the same performance as the original vehicle…more cost-effectively, safer and most importantly in a more fuel efficient manner," added Scheps.

Aluminum Hoods, Trunks, Doors and Bumpers Drive Growth

Aluminum is already the leading material in powertrain and wheel applications and the survey indicates it is quickly gaining market share in hoods, trunks, doors and bumpers. Body, bumper and closure content grew by 58 percent from 2009 to 2012, with 30 percent of all hoods on 2012 vehicles being aluminum; saving a total of 100 million pounds of vehicle weight across the entire fleet. Twenty percent of all bumpers in 2012 will be aluminum.

According to the report, future growth in auto aluminum usage will be primarily driven by these and other applications being converted from steel. For example, the trend line for aluminum hood penetration predicts a minimum share for aluminum of 41 percent by 2017 and 53 percent by 2025.