Increased aluminum in automobiles saving weight and fuel consumption.

The amount of aluminum used in new European cars has risen from 110 lbs. (50 kg) in 1990 to 291 lbs. (132 kg) in 2005, and the achieved weight savings will lead to an annual fuel savings of 1 billion liters, according to a recently released study.

U.S. automobile producers recently have seen slightly lower increases, according to reports by Stratecasts Inc., Estero, Fla. The casting forecaster estimates that U.S. automobiles currently include an average of 260 lbs. of aluminum castings per car and light truck. Between 2004 and 2006, domestic aluminum automotive casting shipments have shown a 9% jump. Those increases should continue through 2010.

"Aluminum, magnesium and plastics are to replace gray iron parts to facilitate compliance with Federal Clean Air Act legislation and regulations," says the Stratecasts report.

By 2014, U.S.-produced automobiles are forecast to have 280 lbs. of aluminum castings per car.

The amount of aluminum per automobile in Europe is expected to grow another 55 lbs. (25 kg) by 2010.

Already, in 2005, 2 million metric tons of aluminum components were put on European roads in new passenger cars. In addition to preserving fuel, the achieved weight savings will lead to roughly 40 million metric tons of C[O.sub.2] emissions over the lifespan of the vehicles.

The study, by Knibb, Gormezano & Partners (KGP), Castle Donington, Derbyshire, England, in cooperation with the European Aluminium Association (EAA), includes data from automotive companies and suppliers, EAA member companies and past data from KGP. The study is based on the analysis of the 15 million cars produced in Europe in 2005 and investigates 20 body components, 17 chassis and suspension components and 25 powertrain components.

The study focuses on different aluminum castings, extrusions, forgings and sheets. In the car body, the largest quantities of components made from aluminum are in air conditioning systems, bonnets, bumper beams and steering columns. Aluminum parts in the chassis and suspension section of cars are mainly wheels, suspension arms and steering components. Cylinder heads, cylinder blocks, engine covers, pumps and radiators represent the majority of aluminum components in the drivetrain of new cars. Today, a growing amount of aluminum is being used in closures, body structure and chassis applications.

In the U.S. going forward, Stratecasts forecasts that automotive component producers can expect that 50% of their parts will be die cast by 2014. The remainder will be cast in permanent mold and green sand.

"As 100 kg (220 lbs.) of aluminum on a car can reduce C[O.sub.2] emissions per kilometer by 9 grams (0.3 ounces), aluminum as material for light-weighting cars has a clear advantage," said a press release issued by the European researchers. "With the continual introduction of further advantages in the design and manufacturing processes, the trend to increase the amount of aluminum per car will continue. Aluminum will certainly play an important role in future generations of sustainable cars."