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Aluminum Assumes Number Three Position in Auto Materials

7 August 2000

Aluminum Assumes Number Three Position in Auto Materials

     Aluminum Passes Plastic With Average Content of 257 lbs Per Vehicle

    TRAVERSE CITY, Mich., Aug. 7 A little test: What do the
Space Shuttle, the HUMMER vehicle, and the Ferrari 360 Modena have in common?
    Answer: They are made from high performance aluminum, the material
automakers are increasingly choosing to improve fuel economy, reduce emissions
and enhance vehicle performance.  American Metal Market (AMM), a metals trade
journal, recently reported that aluminum will surpass plastic in the upcoming
model year to become the third most-used material in light vehicles.
    "Steel and iron are the only materials still ahead of aluminum on the
content scale, and iron interests have a lot to be concerned about in the
competition from aluminum," AMM reported last week.
    According to AMM, high performance aluminum is the fastest growing class
of major materials in the domestic auto market.
    Last week's announcement that the Ford Motor Company will improve the fuel
economy in its SUVs is another signal that aluminum usage will increase even
faster.
    "Automakers are responding to consumer demands for cleaner, more efficient
and safer cars and trucks.  Hybrid-electric technologies get lots of
attention, but cost and complexity are preventing their immediate, widespread
use," said Dr. Richard Klimisch, vice president of The Aluminum Association.
    "Engineers know that aggressive weight reduction is the best way to
improve fuel economy, emissions and performance.  For these reasons, as well
as improved corrosion resistance and recyclability, automakers are more and
more turning to lightweight, high-strength aluminum."
    Automakers have known for years that aluminum improves vehicle
performance, but they've mostly applied it to specialty vehicles or very high-
performance models.  Examples include Acura's NSX, Audi's flagship A8 luxury
sedan and the civilian HUMMER.
    As manufacturing methods have advanced, the aluminum advantage has become
increasing affordable.  Several production vehicles prove the feasibility of
affordable and environmentally friendly aluminum-bodied vehicles.  GM's EV1,
the world's first modern electric vehicle, uses an advanced aluminum
structure.  Also equipped with a lightweight aluminum frame, the Honda Insight
achieves an unprecedented 70 mpg on the highway.
    The big news this year for aluminum cars is the introduction of Audi's A2,
the world's first high volume (60,000 units a year) aluminum-intensive
vehicle.
    According to AMM, examples of parts being converted from iron and steel to
aluminum for 2001 models include:

    *  Front fenders and hoods on Ford's redesigned four-door Explorer and
       Mountaineer SUV.
    *  Deck lids, bumper beams, hoods and wheels on the redesigned Oldsmobile
       Aurora.  V-6 models will use aluminum-intensive suspensions.  The
       Aurora will contain an estimated 480 pounds of aluminum.
    *  Aluminum engines will replace heavy iron units in GM's new Duramax 6600
       turbo diesel V-8 in model year 2001 GMC and Chevrolet 2500 and 3500
       pickup trucks, crew cabs and other vehicles.

    Another reason for the increasing use of aluminum is the superior strength
of aluminum.  On a per pound basis, aluminum is twice as strong as steel,
which allows the designer to provide strong, yet lightweight, crumple zones.
These help protect vehicle occupants from injury in all kinds of collision.
In addition, the use of aluminum in light trucks reduces the weight
differential between cars and trucks, thereby reducing the risk of serious
injuries to car passengers.
    At the same time, aluminum-intensive trucks and SUVs enjoy greater fuel
economy while maintaining or improving the capacity for towing, hauling and
payload.
    "We applaud Ford's commitment to make more environmentally-friendly SUVs.
We're anxious to work with Ford Motor Company and other automakers to help
them sell more cars and trucks with the added performance, safety and
efficiency inherent in aluminum-intensive vehicles," Klimisch said.  "In the
end, the real winners are consumers who will drive better performing vehicles,
while spending less money on fuel."