Seven out of 10 new pickup trucks made in N America will be aluminium-bodied by 2025

By 2025, more than 75 percent of all new pickup trucks produced in North America will be aluminium-bodied, according to a survey of automakers conducted by Ducker Worldwide, global consulting and research firm.

The Aluminum Association’s Aluminum Transportation Group (ATG) commissioned Ducker Worldwide to conduct the ‘2015 North American Light Vehicle Aluminium Content Study’. Through detailed in-person interviews with automotive original equipment manufacturers (OEMs), component suppliers and regulators, Ducker Worldwide maintains a comprehensive material use database to track material and mass of individual components for every vehicle model manufactured in North America. The findings of the study were compiled using data updated and verified between October 2013 and April 2014.
The study, which confirms a major breakthrough for automotive aluminium into high-volume vehicles, surveyed all major automakers and reports Ford, General Motors and Fiat Chrysler will become the biggest users of aluminium sheet in the next decade. It also forecasts that the number of vehicles with complete aluminium body structures will reach 18 percent of North American production, from less than one percent today. Vehicle segments revealed as emerging aluminium content leaders are pickup trucks, sport-utility vehicles (SUVs) and both midsized and full-size sedans.
The study finds that every leading automaker will have numerous aluminium body and closure programs by 2025. As the material mix for body and closure parts continues to change dramatically in the years to come, use of aluminium sheet for vehicle bodies will increase to 4 billion pounds by 2025, from 200 million pounds in 2012.

“The numbers tell a powerful story of aluminium’s explosive growth across the automotive sector,” said Tom Boney, chairman of the Aluminum Association’s Aluminum Transportation Group and vice-president and general manager of automotive for Novelis in North America. “Within the next 10 years, seven out of 10 new pickups produced in North America will be aluminum-bodied, and so too will be more than 20 percent of SUVs and full–sized sedans. Aluminium-bodied cars and trucks are coming in a big way – and soon. Consumers won’t visibly notice a different metal under the paint, but they’ll see greater savings at the gas pump and experience better performance and handling at the wheel,” added Boney.
Additional findings include:

• For 2015, pickup trucks will contain the most aluminum at 548.9 pounds per vehicle, followed closely by E-segment sedans at 546.9 pounds SUVs at 410.3 pounds. and minivans at 396.5 pounds.

• The average aluminum content in 2015 will be up 44 pounds per vehicle or 13 percent over 2012.

• Total North American light vehicle aluminium consumption will increase 28 percent in 2015 over 2012.

• Tesla, Mercedes, BMW and Ford will all exceed the average aluminium content and the average aluminum share of kerb weight for 2015.

• By 2025, 26.6 percent of all the body and closure parts for light vehicles in North America will be made of aluminium.

• Total North American aluminium content in 2025 will be 10 billion pounds.

• Aluminium hood penetration will reach 85 percent and doors will reach 46 percent; complete bodies will reach 18 percent, from less than one percent today.

• Globally, light vehicle aluminium content will approach 35 billion pounds by 2025 making light vehicles the most important global market for aluminium.