1. The Aluminum Advantage
Exploring Commercial Vehicle Applications
Randall Scheps
Chairman, The Aluminum Association’s
Auto & Light Truck Group
Marketing Director, Alcoa Ground Transportation
www.autoaluminum.org

2. Defining Who We Are
2

3. Our Mission
• Central resource for
the automotive
industry on aluminum
• Promote research and
programs highlighting
advantages
• Expanding mission to
include commercial
vehicles
www.autoaluminum.org
3

4. Aluminum Builds a Better Vehicle
Mass Better Fuel Economy
Reduction
Infinitely Reduced
Recyclable Emissions
Enhanced
Performance Improved Safety
4

5. Association Sponsored Automotive
Research
• Safety: Size vs. Weight (DRI Impact of Vehicle Weight Reduction on Fuel Economy for
2004) Various Vehicle Architectures (Ricardo 2007)
• Vehicle Structure -
Manufacturing and Lifecycle 15
Cost Analysis (IBIS 2005) 13
• Improving Sustainability in the
% Fuel Economy Improvement
11
Weight reduction & resizing
Transport Sector Through 10% 6-7%
9
Weight Reduction and the
Application of Aluminum (IAI 7
2006) 5
• Benefit Analysis: Use of 3
Aluminum Structures in 1
Conjunction with Alternative 0 5 10 15 20 25
Powertrain Technologies in % Weight Reduction
Automobiles (IBIS 2008) Small Car - Resized Engine
Large SUV - Resized Engine
Mid Size Car - Resized Engine
Truck - Resized Engine
Small SUV - Resized Engine
Small Car - Baseline Engine
• Aluminum Growth Study Mid Size Car - Baseline Engine Small SUV - Baseline Engine Large SUV - Baseline Engine
Truck - Baseline Engine
(Ducker 2009 & 2006)
5

6. Why We Are Here Today
• Lightweighting with aluminum can help you achieve your
goals
– Auto companies and other third-parties acknowledge aluminum’s
value proposition will help them meet 2016 CAFE standards
– Success experienced in auto industry and same model can apply to the
commercial vehicle industry
• Overview
– Value proposition
– Weight saving benefits
– Research and data
6

7. Why Aluminum for Commercial Vehicles?
THE VALUE PROPOSITION
• Increased payload
• Lower maintenance costs
• Reduced fuel
consumption
• Reduced greenhouse gas
emissions
• Improved durability
• Higher resale value
• Infinitely recyclable
7

8. Truck Owners See Value in Lightweighting
Source: Alcoa 2008, Q4 research 8

9. Aluminum Already on the Road
• Cab structure The average Class 8 Tractor today contains
1,000 lbs. of aluminum
• Forged aluminum wheels
• Fuel tanks
• HVAC components
• Bellhousing
• 5th wheel
• Landing gear
• Trailer side walls and structure
• Tank bodies
9

10. Potential Future Applications
• Emerging technologies help save more weight
– Save 3,500 lbs. versus today’s truck and trailer with aggressive weight
reduction
Cab Rear Wall Rear Door
Cab Roof Save 49 lbs. RR Door Surround Save 187 lbs.
Save 60 lbs. Save 150 lbs.
Save 20 lbs.
per door Side Wall
Save 1,000 lbs.
Cab Floor
Save 56 lbs.
Landing Gear
Save 50 lbs.
Slider Box
Frame Rails Cab X-Member Save 150 lbs.
Save 435 lbs. Stair/DPF Module Save 38 lbs. Save 30 lbs. per
Save 37 lbs.
wheel
10

11. Research Supporting Our Value Proposition
• Potential Savings as a Result of Weight
Reduction (IFEU Heidelberg 2003)
• Improving Sustainability in the
Transport Sector Through Weight
Reduction and the Application of
Aluminum (IAI 2006)
• Simulator Data (Major Tire
Manufacturer 2007)
• Case Study: China Bus Project (Alcoa
2008)
• Impact of Weight on Rolling Resistance
and Fuel Economy (Smithers 2009)
11

12. IFEU Heidelberg Research Findings
• Weight is a factor in truck
and bus fuel economy
• Trucks and buses represent
a large potential fuel
savings
• CO2 reductions also
• Duty cycle dependant
• Results based on real-
world experience of truck
OEMs
Source: IFEU, SGKV 2002 12

13. Estimated Fuel Economy Benefit from
10% Weight Reduction
9.0%
8.0%
8.0%
7.0%
Percent Increase in Fuel Economy
6.0% 5.5%
5.0%
4.0%
3.0%
2.4%
2.0% 1.6%
1.0%
0.0%
Truck Truck Bus Bus
Volume Constrained Weight Constrained City Distance
Source: IFEU, SGKV 2002 13

14. Impact More Pronounced in Urban Setting
Bus Example
Physical resistances have an impact on Heavier buses consume more fuel in urban areas
vehicle fuel efficiency and mass of the
vehicle is a significant factor
3. Gradient Resistance
FSt = m. g. sin a
G = m. g.
Lightweighting will enhance fuel consumption
Impact is more pronounced in urban setting
Source: IFEU, Alcoa 14

15. Rolling Resistance Lab Test
• Research conducted by
third-party firm (Smithers)
• Tested to SAE spec and
followed U.S. EPA
Smartway protocol
• Five test runs completed
at varying loads and tire
pressures
15

16. Light Weight Pays Fuel Economy
Dividends
An aluminum wheel
can improve tire
rolling resistance by
up to 3% over a
comparable size
steel wheel
Source: Smithers Scientific Services 16

17. Light Weight Pays Fuel Economy
Dividends
40
Steel
35 Aluminum
Rolling Resistance (lbs)
30
25
3% reduction in rolling resistance equates to
20 1% fuel savings reduction in rolling resistance
3%
equates to 1% fuel savings
15
10
3000 3500 4000 4500 5000 5500 6000 6500 7000
Load (lbs)
Source: Smithers Scientific Services 17

18. Major Tire Manufacturer Simulator Data
Fuel Economy Improvement Per 10% Weight Save
9.0%
8.4%
8.0%
7.0% 6.7%
6.3%
6.0%
Percent Improvement
5.0%
4.0%
3.0%
2.0%
1.0%
0.0%
Medium Duty Heavy Duty Bus
Base Weight 16,340 36,312 24,511
Drive Cycle HTUF Regional HTUF
Source: Major Tire Manufacturer 18

19. China Bus Project: Real World Success
Weight 6% Fuel
50 tons of CO2
Reduction of Economy
Lifetime
1,400 kg (12%) Improvement
Value – Ecological Space Frame
Extrusions
• Reduction in CO2 emissions
• Reduced road surface wear
and tear
Value – Financial
• 6% less fuel
• Maintenance savings (tires, Wheel
brakes, suspension) Body Panel
• Improved corrosion resistance
• Payback of 2-3 years
Source: Alcoa 19

20. IAI Transport Model Illustrates Potential
CO2 Savings from Lightweighting
User Input Output
Specifications of
Final energy savings
vehicles and
through lightweighting
components
CO2 equivalent savings
Customer scrap
thought lighweighting
generation
IAI/EAA/AA Carbon footprints of
Fuel/electricity
consumption Transport aluminum and
competing material
during use Lifecycle
Vehicle recycling
Model
Industry Inputs
CO2 equivalents
Final energy
Aluminum production
date
Source: IAI Study 2008
Source: IAI 20

21. IAI: Aluminum Helps Reduce CO2
• Auto aluminum already Specific Savings
(Tons of CO2 per ton of w eight save)
saving 300 million metric
tons of CO2 annually 60
53
• Including CO2 impact of 50
aluminum production 40
28
• Use-phase savings far 30
23
18
outweigh production CO2 20
generation 10
3
0
• Recycled aluminum uses
Constrained
Constrained
Bus - Urban
Car
Suburban
Bus -
Truck -
Truck -
Volume
Weight
95% less energy
Potential Weight Savings: 3,000-3,500 lbs. 3,500-4,500 lbs 300-500 lbs
Source: IFEU, 2003 21

22. Aluminum is a Part of the Solution
More Payload AND Lower Costs
• One ton of weight reduction = up to
2,000 gallons of diesel per year Global CO2 Sources
• Lower maintenance costs
• Lower tire and brake costs
Higher residual value and durability
• Corrosion resistant parts last longer
Reduced Lifetime CO2 Emissions
• Save 18 tons of CO2 for every ton of
aluminum you add to your fleet
Reduced dependence on imported oil
Infinitely recyclable
22

23. Questions?
23

24. The Aluminum Advantage
Exploring Commercial Vehicle Applications
Randall Scheps
Chairman, The Aluminum Association’s
Auto & Light Truck Group
Marketing Director, Alcoa Ground Transportation
www.autoaluminum.org