Use of Aluminum Could Reduce Cost of EVs by $3,000

By Eric Loveday

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According to a new study jointly conducted by the Aluminum Association Inc, and Ricardo a technical research and consultant firm for automotive industries, the use of aluminum in plug-ins, hybrids, and full EVs could reduce vehicle costs by $3,000.

The study shows that the use of aluminum frame and suspension components rather than steel can reduce the weight of a vehicle by 10%.  This weight reduction would reduce the load on the batteries powering these vehicles and therefore, automakers could downsize battery packs netting a reduced cost of approximately $3,000.

The study was released at the Business of Plugging In conference held in Detroit this week.  Highlights of the study are listed below.

• The driving range of the vehicles could be improved approximately equal to the mass saved.  Reduce the mass of the vehicle 20 percent, go 20 percent father. One example vehicle had the range extended from 80 to 97 miles.
• The heaviest vehicle in the study, at 1,822 kg, consumed about 300 Wh/mi, while the lightest at 627 kg consumed about 146 Wh/mi.
• Regenerative braking could recover about 65 percent of the energy associated with the vehicle’s momentum irrespective of the vehicle weight. But this is only about 15-20 percent of the total energy expended.
• For the lightest vehicle, about 44 percent of the energy is lost to powertrain inefficiencies, with 33 percent of the energy used to overcome air resistance, and only 24 percent is used to move the vehicle.
• As with conventional vehicles, the lighter vehicles have faster accelerations.

According to Micheal Bull, Director of Automotive Technology for Novelis, "As automakers gear up for a new generation of plug-in electric vehicles, the high cost of battery power remains a barrier.  What this new report shows is that by upgrading from traditional steel to an advanced aluminum body structure, the vehicle’s stored energy requirements can be cut by about 10 percent, which could save up to $3,000 per vehicle since less power and energy is required to move the lighter vehicle.”

All of the highlights of the study as well as the statements made by Bull ignore one important fact.  Aluminum is significantly more expensive in vehicle applications than steel. 

This negates some of the savings potential, but does not undercut the research.  Lighter vehicles less power, have a longer range or better efficiency, and accelerate better.  This formula applies to traditional vehicles as well as the plug-in variety.

Source:  The Aluminum Association Inc. Press Release

Detroit, October 20, 2009 – Opting for high-strength, low-weight aluminum over heavier steel structures for plug-in electric and hybrid vehicles can cut vehicle price overall by reducing the battery energy requirements and  the associated  costs, according to a new study released today at the Center for Automotive Research’s (CAR)  Business of Plugging In conference. The study was jointly conducted by The Aluminum Association, Inc. with Ricardo, a leading technical research and strategic consultancy to the world's automotive, transport and energy industries.

Michael Bull, Director of Automotive Technology for Novelis, Inc., represented the Aluminum Association at the conference and participated in a panel discussion on future automotive changes associated with all electric vehicles.

“As automakers gear up for a new generation of plug-in electric vehicles, the high cost of battery power remains a barrier,” said Bull. “What this new report shows is that by upgrading from traditional steel to an advanced aluminum body structure, the vehicle’s stored energy requirements can be cut by about 10 percent, which could save up to $3,000 per vehicle since less power and energy is required to move the lighter vehicle.”