A new study states that reducing vehicle weight with aluminum is the best overall enabler for significant fuel efficiency increases. The report specifically shows that achieving new higher fuel economy standards in the 50+ MPG range is possible by combining a range of technologies that include weight reduction with advance materials. The study was conducted by a member of the AVL Group, the world’s largest independent company for the development of powertrain systems and a partner to many in the automotive industry.

The study showed no single technology approach will cost-effectively achieve the new US 54.5 miles per gallon (MPG) fuel economy target on its own, but that substituting lower weight through the use of aluminum in automobiles is the one consistent and cost-effective strategy that can be combined with all other efficiency improvement strategies and technologies to maximize their ability to meet the new target.

The new study, conducted by Detroit-based Scenaria (but funded by the Aluminum Association’s Aluminum Transportation Group (ATG)) found:

• There is no single vehicle technology strategy that can cost-effectively achieve a 50+ MPG fuel economy target without significant weight reduction.
• Weight reduction can be done with materials substitution – such as switching from steel to low-weight, high-strength aluminum – to avoid less desirable downsizing of vehicles.
• Weight reduction helps save automakers money by providing flexibility in decisions to use other often more expensive technologies as part of their approach to improving fuel economy.
• Weight reduction with aluminum is a cost-effective complement to maximize the benefits of all other fuel economy improvement technologies.

“High-volume aluminum intensive cars and trucks will be in showrooms within the next few years. As automakers continue to evolve vehicle design, they recognize aluminum’s advantages, and expect to double their use of aluminum as they move to meet the demand for more fuel efficient vehicles,” said ATG Technical Committee Chairman Doug Richman. “With aluminum, newer vehicles can weigh less without getting smaller, and consumers ultimately will benefit from higher-mileage, lower-emission cars and trucks that remain durable, safe, cost-effective and high performing.”

Ford CEO Allan Mulally recently confirmed to the news media that his company also intends to use even more aluminum.  On Sept. 18, Mulally told CBS News, “We have been adding more aluminum. I can tell you as an airplane person, aluminum is very durable and very strong. And the neat thing is that it brings such a reduction in weight. And so clearly, back to fuel efficiency again and durability and quality, we’re going to see more and more of these alloys going forward, to the benefit of the customer.”

Another OEM extolling the benefits of aluminum is Jaguar Land Rover who recently released this video showing the production of the new aluminum body Range Rover.