Aug 4 2010
Substituting high strength, low weight aluminum for more traditional materials in Class 8 truck and trailers can eliminate 3,300 pounds from the vehicle weight, according to a new report released today by Ricardo Inc.
Based on these findings, aluminum could yield annual savings of fuel and emissions in Class 8 trucks and trailers as high as 1,612 gallons and 17.9 tons of CO2. When considering these results for the total United States fleet, approximately two million vehicles, the overall economic and environmental impact of weight savings may be one billion gallons of diesel and 10 million tons of CO2 per year.
Driven largely by payload considerations, aluminum has experienced more than 30 years of continual growth in commercial applications. Today, the average Class 8 vehicle uses over 1,000 pounds of aluminum; however, this new study confirms that by further reducing overall vehicle weight with aluminum, transporters can load their vehicles with an additional 6.5 percent of payload at gross vehicle weight (GVW). This equates to fewer trips and an “effective” fuel and emissions savings of 6.5 percent for equivalent average ton-mile freight efficiency.
“With many challenges facing the commercial vehicle industry, including fuel and operating costs, greenhouse gas emissions, and federal mandates that add weight to vehicles, high strength, yet low weight aluminum offers cost-effective, real-world solutions available today,” said Randall Scheps, Chairman of the Aluminum Association’s Aluminum Transportation Group and Alcoa’s Director of Ground Transportation.
The study conducted by Ricardo Inc. was commissioned by the Aluminum Association Inc.’s Aluminum Transportation Group (ATG) to analyze the fuel efficiency impact of lightweighting Class 8 trucks and trailers. The study simulated different configurations of vehicles and payload conditions (i.e. unloaded, gross vehicle weight [GVW] and half-GVW load) for the major drive cycles that represent commercial transportation in the United States.
In addition to the impact of weight savings alone, the study analyzed the combination of weight savings and aerodynamic drag reduction. When combining the weight reduction potential available with an 8 percent improvement in aerodynamic drag, the overall fuel economy improvement for an aluminum intense vehicle relative to the conventional vehicle was as high as 8.2 percent.
“Opting for advanced aluminum solutions over traditional steel applications in Class 8 trucks and trailer construction creates opportunities for the industry to increase fuel efficiency and payload capacity, decrease operating costs, and reduce greenhouse gas emissions. The return on investment for switching to more advanced materials like aluminum is even higher when lightweighting is combined with other improvements like aerodynamics, engine optimization, and low rolling resistance,” continued Scheps.
Using aluminum to reduce vehicle weight in commercial vehicles has other benefits aside from increased payload, fuel efficiency, and reduced emissions. These include lower maintenance costs due to fewer trips and less miles on the truck, which ultimately reduces wear and tear on brakes and tire treads. Aluminum components also are corrosion resistant, which decreases the need for rust repair and extend the life of the truck. In addition, aluminum is one of the most recycled materials on the planet and is infinitely recyclable, meaning commercial vehicle aluminum applications never need to be landfilled. And, recycling aluminum saves nearly 95 percent of the greenhouse gas emissions (CO2 equivalent) associated with primary aluminum production.