Speaking at Automotive Megatrends USA – organised and hosted by Automotive World, Doug Richman, Vice President of Engineering at Kaiser Aluminum, says that utilising aluminium to reduce mass will be key in meeting CAFE regulations in 2025.
Part of the puzzle
Richman explained that current applications of aluminium are allowing OEMs to realise significant weight savings; 1lb of aluminium in passenger cars replaces 1.5lb-2lb of steel, and for body in white (BIW) savings of 350-450lb can be made. “Most of the OEMs have come out and say they expect to shed between 300-400lb as part of their technology approach to 2025,” he says.
There is a huge challenge in meeting CAFE regulations in 2025, and vehicle lightweighting is only part of the puzzle. “We are 10% of the solution. Powertrain development will probably lead at least 50% of the way for the standards at 2025. We are part of the solution, not the solution,” observes Richman.
Safe and efficient
He adds that there are specific benefits to mass reduction, regardless of how corporate average fuel economy (CAFE) regulations are met: “However we get there, vehicles are going to be safer, and the fleet is better because we have less mass running around, less kinetic energy involved in traffic collisions, better emissions, less corrosion, and improved braking performance. There are a whole range of benefits when vehicles have been lightweighted.”
Richman expects the penetration of aluminium to increase in future as OEMs strive to meet the 54.5mpg target: “Currently, 65% of all wheels are aluminium, cylinder heads are close to 100%, hoods are at 45% for the last ten years, which are expected to go up to 85% by 2025.”
Current applications of aluminium in BIW today are close to 0%, but is expected to rise to about 18% of all light-duty passenger cars by 2025, which Richman expects to be pioneered by the aluminium intensive Ford F150 pick-up.
Freddie Holmes
