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Aluminum Vehicle Structure - Manufacturing and Lifecycle Cost Analysis

Aluminum Vehicle Structure - Manufacturing and Lifecycle Cost Analysis

In this report funded by The Aluminum Association and performed by IBIS Associates, the consumer's vehicle lifecycle cost for conventional gas, diesel, alternative fuel, and hybrid vehicles are compared using lightweight aluminum instead of steel. Since alternative fuel and hybrid vehicles are put at a cost disadvantage due to lower production, all studies were conducted with projected cost as if these vehicles were mass produced. Some factors affecting lifecycle cost are miles per gallon, materials, components, initial price, and maintenance. It's concluded that using aluminum in place of steel will lower the overall lifecycle price of all types of vehicles. However, in the current market the overall lifecycle cost of a conventional gas vehicle will still be less expensive than a hybrid vehicle despite the higher miles per gallon of the hybrid. IBIS has conducted studies for OEM, Tier 1, and material suppliers on material economics, manufacturing, operation, and disposal/recycle costs (slide4). For more info on IBIS visit


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