Alcoa & Metalsa’s new aluminium frame for CVs 40% lighter than steel frames

Lightweight, high-performance metals company Alcoa, in collaboration with Metalsa, a global supplier of light and commercial vehicle and chassis structures, recently displayed a lightweight, all-aluminium commercial truck frame at the Mid-America Trucking show in Louisville, Kentucky.

Still under development, the lighter weight frame will reduce truck weight by over 40 percent compared to steel frames, saving nearly 900 pounds (408kg) per vehicle, increasing fuel efficiency and payload. Additionally, the frame’s increased stiffness will double rigidity, enabling a smoother ride. The aluminium frame also offers superior corrosion resistance compared to steel, prolonging the vehicle’s life span.

“The lightweight truck frame will allow fleets to reduce fuel consumption, increase payload without compromising durability,” said Mark Vrablec, president, Alcoa Aerospace Transportation & Industrial Products (ATI).

“Our customers wanted an aluminium frame that would provide 40% weight savings with equivalent performance to steel, and we knew the pathway to that was combining our knowledge of commercial vehicle design with Alcoa’s expertise in lightweight metals,” said Sean Fleming, VP (Technology), Metalsa commercial vehicles.

Experts at the Alcoa Technical Center worked with Metalsa to develop the new frame over the past two years. Demonstration projects are underway to qualify the product with customers. Existing equipment and tooling is being used to allow manufacturers to seamlessly transition to the aluminum frame, with little or no additional capital expense. The frame is expected to be available in 2018, produced using metal from Alcoa’s Global Rolled Products business.