Lightweight Potential of an Aluminium Intensive Vehicle

The EAA Automotive launching event for the 'Alumaximised' Study & the online Aluminium Automotive Manual (AAM), 18.02.2003, Brussels

Univ.-Prof. Dr.-Ing. H. Wallentowitz, Institut für Kraftfahrwesen Aachen (ika)
Dr.-Ing. T. Parr, Institut für Kraftfahrwesen Aachen (ika)
Dipl.-Ing. D. Wynands, Institut für Kraftfahrwesen Aachen (ika)
Dipl.-Ing. Dipl.-Wirt. Ing. R. Wohlecker, Forschungsgesellschaft Kraftfahrwesen Aachen (fka)

Summary:

A lecture presents the results of a theoretical study about the lightweight potential of aluminium in modern day vehicle technology (Fig. 1). This study is intended to provide a weight estimate for all the relevant components of a compact-class car when made using aluminium intensive design. The result of the study provides the weight estimate of an aluminium intensive vehicle taking into consideration the primary and secondary weight savings, this virtual car is known as the 'Alumaximised Car'. As a basis for the analysis a steel reference-car needed to be defined, its dimensions, basic properties, component material and weight were set as the average values for a typical compact-class car.

The first step of the study consisted of transferring all current aluminium applications from existing vehicles to the compact-class using suitable methodologies. The result of this transfer is a state-of-the-art aluminium vehicle. The second step consisted of determining any further weight savings that could be obtained using the latest aluminium technologies, this information was provided with participation of the EAA member companies. In the secondary weight saving analysis the weight of body framing, motor, drivetrain and chassis was estimated due to a downscaling of the vehicle at constant performance. These steps were to result in a minimum and maximum weight saving potential for the 'Alumaximised Car'.




Fig. 1: Procedure of the analysis