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Aluminum’s Role in Meeting
First-Ever Heavy Truck Fuel
Economy Standards
Randall Scheps
Alcoa, Inc.
on behalf of
The Aluminum Association’s
Aluminum Transportation Group (ATG)
Defining Who We Are
The Aluminum Association’s Aluminum Transportation Group (ATG)
www.aluminumintransportation.org
Many Challenges Facing the
Commercial Vehicle Industry Today
• Rising energy
costs
• Growing concern
over greenhouse
gas emissions
• Federal mandates
continue to add
weight to heavy-
duty vehicles
• First-ever fuel
efficiency
standards
Source: International Energy Outlook 2010; U.S. EIA
Freight energy use increasing faster than passenger energy use
Organisation for Economic Cooperation
and Development (OECD) CountriesNon-OECD Countries
Quadrilli
on B
TU
Transportation Energy Consumption
www.aluminumintransportation.org
Federal Mandates Add Weight
New emissions technologies have reduced
fuel economy and increased weight
Emissions MandateAverage Weight
Impact (lbs.)
Fuel Economy Impact
of Emissions
Technologies
2002 EPA Engine Emissions +150 -8%
2007 EPA Engine Emissions +400 -3%
2010 EPA Engine Emissions (SCR) +300 +3%
TOTAL 850 lbs. -8%
www.aluminumintransportation.org
Landmark Fuel Standards for Trucks
• First-ever fuel economy and
greenhouse gas emissions
regulations for medium- and
heavy-duty trucks built from
2014 to 2018
• The rule aims to:
– Reduce annual oil consumption by
530 million barrels
– Cut annual greenhouse gas
emissions by about 270 million
metric tons
www.aluminumintransportation.org
Aluminum’s Potential Recognized
by Regulators
• The EPA and NHTSA
evaluated materials for the
greatest mass reduction
opportunities
– Aluminum
– High-strength steel
– Composites
• Aluminum ranked far above
the others
– “Greatest potential” to safely
reduce vehicle weight while
boosting fuel economy and
cutting emissions
www.aluminumintransportation.org
2010 Industry Sponsored Study on
Lightweighting and Freight Efficiency
• Objective– Quantify fuel economy impact of weight reduction with aluminum specific to U.S. drive cycles
• Methodology– Analytical simulation (Ricardo)
• U.S. drive cycle simulations– EPA HWFET
– WVU Interstate
– HUDDS
• Load conditions– Un-loaded, ½ GVW Load, GVW
• Engine and transmission– Displacement: 13-liter, diesel
– 10-speed automated manual transmission (AMT)
• Vehicle specifications– Frontal area: 10.68 m2
– Coefficient of drag (Cd): .60 (baseline)
Source: Ricardo
Photo Credit: East Manufacturing
www.aluminumintransportation.org
Vehicle Configurations Studied
Source: Ricardo
Tractor
(lbs.)
% Weight
Saved
Trailer
(lbs.)
% Weight
Saved
Tractor &
Trailer
(lbs.)
% Weight
Saved
Conventional (baseline) 16,000 13,500 29,500
“Traditional” Lightweighting 15,500 3.1% 12,500 7.4% 28,000 5.1% (1,500 lb)
“High” Aluminum Content 14,500 9.4% 11,700 13.3% 26,200 11.2% (3,300 lb)
Save 30 lbs. per
wheel
Cab rear wall
save 49 lbs.
Save 20 lbs.
per door
Frame rails
save 435 lbs.
Cab 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.
Side Wall
Save 1,000 lbs.
Rear door
save 187 lbs.
www.aluminumintransportation.org
Payload Configurations Studied
Source: Ricardo
Vehicle
Configuration
Tractor Mass
(lbs.)
Trailer Mass
(lbs.)
Payload
(lbs.)
Total (lbs.)
Conventional
(baseline)16,000 13,500
50,500 80,000 GVW
“Traditional”
Lightweighting15,500 12,500
52,000 80,000 GVW
“High”
Aluminum
Content
14,500 11,700
53,800 80,000 GVW6.5% more payload
6.5% fewer trips
www.aluminumintransportation.org
Payload Configurations Studied
Source: Ricardo
Vehicle
Configuration
Tractor Mass
(lbs.)
Trailer Mass
(lbs.)
Payload
(lbs.)
Total (lbs.)
Conventional
(baseline)16,000 13,500
50,500 80,000 GVW
25,250 54,750 half load
0 29,500 unloaded
“Traditional”
Lightweighting15,500 12,500
52,000 80,000 GVW
25,250 53,250 half load
0 28,000 unloaded
“High”
Aluminum
Content
14,500 11,700
53,800 80,000 GVW
25,250 51,450 half load
0 26,200 unloaded11.2% mass
saved
www.aluminumintransportation.org
U.S. Drive Cycles Simulated Via
Physics-Based Model
Highway Fuel Economy Test
(HWFET)
– One of EPA’s official highway
cycles
– Duty cycle designed for
medium to high speed
operation, no mid-cycle stops
West Virginia University
Interstate Drive Cycle
(WVUIDC)
– Simulates interstate operation
– Speeds vary from medium to
high, many moderate
acceleration events
Heavy-Duty Urban
Dynamometer Drive Schedule
(HUDDS)
– One of EPA’s drive cycles for
heavy-duty vehicles
– Several idle and start-stop
positions
– Many acceleration and
deceleration events
Source: Ricardo www.aluminumintransportation.org
3.00
5.00
7.00
9.00
11.00
13.00
0 10000 20000 30000 40000 50000 60000
Fu
el E
co
no
my (
mp
g)
Weight Reduction (lbs)
Transient Drive Cycles
HWFET
HUDDS
WVUIDC
Weight Savings Increases
Fuel Economy for All Drive Cycles
Source: Ricardo
GVW Unloaded
www.aluminumintransportation.org
Weight Reduction and Aerodynamic
Improvements are Complimentary
“High” Aluminum Content Truck
Source: Ricardo
• Weight savings has
greater impact at
lower drag coefficient
• 3,000 lb. reduction
equivalent to 0.05 Cd
improvement
3.00
4.00
5.00
6.00
7.00
8.00
9.00
10.00
11.00
12.00
0 10000 20000 30000 40000 50000 60000
Fu
el E
co
no
my (
mp
g)
Weight Reduction (lbs)
HWFET
0.45
0.5
0.55
0.6
0.65
GVW Unloaded
www.aluminumintransportation.org
Aluminum Impacts
Fleet Freight Efficiency
“High” Aluminum Content – 3,300 lb. Weight Reduction
Payload
(% GVW)% Annual Miles*
Fuel Efficiency
Improvement
0 – 25 % 10 % 4.1 %
25 – 75 % 25 % 3.7 %
75 – 100 % 65 % 6.5 %
Fleet Average = 5.7 %
* Average results from Aluminum Association Heavy-Duty Truck Use Survey
Source: Aluminum Association
6.5% more
payload /
fewer trips
www.aluminumintransportation.org
Weight Reduction Technology List in
New Heavy Truck Fuel Economy Rule
• OEMs are able to
overachieve in
the weight
reduction
category beyond
the 400lb
baseline
• Weight reduction
is manually
calculated by
OEM from the list
and inputted into
GEM
Primary
Weight
Reduction
Options
Secondary
Weight
Reduction
Options
www.aluminumintransportation.org
Forged Aluminum Wheels
16
10 Forged Alu Wheels/Tires = 2,170 lbs
18Steel Wheel/Tires =2,000lbs
18 Steel Wheel/Tires = 3,420 lbs
Weight Reduction
1,250lbs per
tractor/trailer
www.aluminumintransportation.org
Total Weight: 19.85 kg
Cross Members
3.33 kg
2.46 kg
8.27
kg
• 42% weight savings
vs steel (4lbs -
38lbs per
crossmember)
• 7 Cross members
per truck
• 101 lbs per truck
saved vs. steel
Aluminum Cross Member
www.aluminumintransportation.org
www.aluminumintransportation.org
Aluminum Fifth Wheel
• 100lbs weight saved
per truck
• Forged aluminum
construction
• 150,000 lbs drawbar
load
Fifth Wheel
Frame Rails
• Aluminum frame rails = 462 lbs
• 47% weight save per truck (440lbs)
Roll Formed Frame Rails
www.aluminumintransportation.org
• Aluminum extrusion
based upper structure
• Bolted or welded
• 40% weight save vs. steel
(2200 lbs bus / 250-300
lbs typical truck cab)
• 10% improved range on
full-electric powered
version
• Converting chassis would
save another 1100 lbs
Spaceframe Body
Full aluminum bus body – China & Brazil
www.aluminumintransportation.org
Aluminum is Part of the Solution
• More payload– Carry 3,300 lbs or 6.5% more cargo
at GVW
• Improved fuel efficiency– As high as 1,612 gallons each year
for a weight constrained vehicle• Nearly one billion gallons of diesel
annually for the current U.S. fleet
• Reduced CO2 emissions – Up to 17.9 tons annually for a weight
constrained vehicle• Approximately 10 million tons of CO2 per
year for the current U.S. fleet
www.aluminumintransportation.org
Thank You
Contact Us
For additional aluminum research in the areas of safety, cost,
alternative powertrains, growth and sustainability, to sign-up for the
ATG’s monthly newsletter and/or download this presentation,
please visit us online at www.aluminumintransportation.org or
e-mail [email protected]